Workshop Manual Octavia Engine Fuel Injection 1.9tdi

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 ŠKODA
Organisation; it is not permitted to pass it on to third parties.
© 1996 ŠKODA, automobilová 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
Supple- Edition Subject Article Number

ment
08.96 Basic Edition of Workshop Manual S00.5111.50.20
1 05.97 Supplement to Basic Edition S00.5111.51.20
2 03.98 Modifications for Vehicles ä 08.97 S00.5111.52.20
3 02.99 Modification of Fault Code S00.5111.53.20
4 12.00 Modifications for Vehicles 08.00 ä S00.5111.54.20
5 09.03 Supplement to Repair Group 01 and 23 S00.5111.55.20
6 01.04 Supplement to Repair Group 01 and 23 S00.5111.56.20
7
8
9
10
11
12
13
14
15
16
17
18
19
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. Printed in CR
© 2004 KODA AUTO a. s. S00.5111.56.20
OCTAVIA Service
Contents
01 Self-Diagnosis Page
Self-Diagnosis .............................................................................................................................. 01-1
- Properties of the self-diagnosis ................................................................................................ 01-1
- Technical data of self-diagnosis ............................................................................................... 01-1
- Connecting tester V.A.G 1552 and select engine electronics control unit ................................ 01-2
- Interrogating and erasing fault memory .................................................................................... 01-5
- Fault table ................................................................................................................................. 01-8
Actuator diagnosis ...................................................................................................................... 01-18
- Performing actuator diagnosis ................................................................................................. 01-18
- Basic setting ............................................................................................................................. 01-21
- Coding control unit ................................................................................................................... 01-23
Readiness code ........................................................................................................................... 01-24
- Reading readiness code ........................................................................................................... 01-24
- Generate readiness code ......................................................................................................... 01-26
Measured value blocks ............................................................................................................... 01-28.2
- Reading measured value block ................................................................................................ 01-28.2
- Display nominal values for general vehicle inspection ............................................................. 01-29
- Display nominal values for injection pump ............................................................................... 01-38
- Display nominal values for engine idling .................................................................................. 01-46
- Display nominal values for exhaust gas recirculation .............................................................. 01-49
- Display nominal values for temperature sensor ....................................................................... 01-51
- Display nominal values for automotive power .......................................................................... 01-52
- Display nominal values for charge pressure control ................................................................ 01-58
23 Fuel Formation/Injection Page

Servicing a diesel direct fuel injection system ......................................................................... 23-1
- Safety measures ...................................................................................................................... 23-1
- Rules for cleanliness ................................................................................................................ 23-1
- Overview of fitting locations ä 07.97 ....................................................................................... 23-2
- Overview of fitting locations 08.97 ä 07.00 ............................................................................. 23-2.2
- Overview of fitting locations 08.00 ä ....................................................................................... 23-3.1
- Assembly overview of injection pump ...................................................................................... 23-4
- Assembly overview of fuel filter ................................................................................................ 23-5
- Assembly overview of throttle mechanism ............................................................................... 23-6
- Adjusting sender for accelerator pedal position ....................................................................... 23-7
- Disassembling and assembling air filter ................................................................................... 23-7.2
- Removing and installing injection pump ................................................................................... 23-8
- Dynamically testing and setting commencement of injection ................................................... 23-13
- Removing and installing and testing injection nozzles ............................................................. 23-16
- Wiring and Component Test with Test Box .............................................................................. 23-19
- Replacing engine control unit ................................................................................................... 23-20
Inspecting the charge air pressure system .............................................................................. 23-22
- Inspecting charge air pressure ................................................................................................. 23-22
- Inspecting charge pressure control solenoid valve (N75) ........................................................ 23-24
- Inspecting intake manifold temperature sender (G72) ............................................................. 23-25
- Inspecting intake manifold pressure sender (G71) and altitude sender ................................... 23-26
- Hose layout plan for charge pressure control ........................................................................... 23-27
Testing injection control ............................................................................................................. 23-28
- Testing injection timing device control range ............................................................................ 23-28
- Testing the commencement of injection valve (N108) ............................................................. 23-29
- Inspecting fuel temperature sender .......................................................................................... 23-30
Edition 01.04 ------------ I ------------

S00.5111.56.20
Service OCTAVIA
Inspecting exhaust gas recirculation system ........................................................................... 23-32
- Inspecting exhaust gas recirculation ........................................................................................ 23-32
- Inspecting exhaust gas recirculation valve (N18) ..................................................................... 23-34
- Inspecting air mass meter (G70) .............................................................................................. 23-35
- Vacuum plan of hose layout plan for the exhaust gas recirculation system ............................. 23-37
Inspecting control units input quantities .................................................................................. 23-38
- Testing voltage supply for diesel direct injection system .......................................................... 23-38
- Testing engine speed sender (G28) ......................................................................................... 23-41
- Testing needle lift sender (G80) ............................................................................................... 23-42
- Testing coolant temperature sender (G62) ............................................................................... 23-43
- Testing brake light switch and brake pedal switch ................................................................... 23-44
- Testing modulating piston movement sender (G149) and metering adjuster (N146) ............. 23-45
- Testing accelerator pedal position sender (G79) ...................................................................... 23-47
Testing auxiliary signals ............................................................................................................. 23-49
- Testing signals from/to the air conditioning system .................................................................. 23-49
- Testing clutch pedal switch (F36) ............................................................................................. 23-51
- Testing speed signal ................................................................................................................. 23-52
- Testing engine speed signal ..................................................................................................... 23-53
- Activating or deactivating cruise control system ....................................................................... 23-54
- Testing cruise control system ................................................................................................... 23-55
- Testing CAN-Bus databus ........................................................................................................ 23-55.3
Servicing intake manifold 08.97 ä ............................................................................................ 23-56
- Inspecting the change-over of the intake manifold flap ............................................................ 23-57
- Hose layout plan for intake manifold flap operation ................................................................. 23-59
28 Glow plug system Page

Inspecting glow plug system ..................................................................................................... 28-1
- Inspecting proper operation ...................................................................................................... 28-1
- Inspecting glow plugs ............................................................................................................... 28-2
- Inspecting glow period warning lamp ....................................................................................... 28-2
------------ II ------------ Edition 01.04

S00.5111.56.20
OCTAVIA Self-diagnosis 01
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 com-

ponents, these are stored in the fault memory
together with an indication of the fault type.
The engine control unit analyses this fault infor-

mation 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 (sporadi-

cally), are displayed as sporadic by the addi-
tion /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 auto-
matically erased from the fault memory.
The stored faults can be read out with the vehi-

cle 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 dis-
play of the vehicle system tester, look for the
appropriate text in the fault table on the ba-
sis of the fault code.
♦ Use of the fault reader V.A.G 1551 (with pro-
gramme card version 8.0) with integrated
printer, or VAS 5051, is similar. Slight varia-
tions are possible in the readouts in the dis-
play.
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 se-
lected ⇒ page 01-2.
Edition 12.00 ------------ 01-5

01-1 ------------
S00.5111.54.20
01 Self-diagnosis OCTAVIA
Functions available when using vehicle sys-

tem tester V.A.G 1552
Please refer to the table below for the require-

ments necessary to enable you to select the
desired functions.
Function Condition
Engine not Engine

running, idling
ignition on
01 Interrogate control unit yes yes

version
02 Interrogate fault memory yes1) yes
03 Final control diagnosis yes yes
04 Basic setting no yes

05 Erase fault memory yes yes
06 End output yes yes
07 Code control unit yes no
08 Read measured value yes yes
block
1) 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

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 con-

nected:
- 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 proce-
dure, refer to the following notes:
Notes:
♦ If Error in data transmission is displayed
because of an input error, disconnect cable
01

at vehicle system tester, plug it in again and
repeat the steps.
Test of vehicle systems HELP K ♦ If one of the following messages appears in
Control unit does not answer the display, perform fault finding according
to diagnostic cable fault finding programme:
⇒ Current Flow Diagrams, Electrical Fault
Test of vehicle systems HELP Finding and Fitting Locations binder, or
Error in establishing communication ⇒ Operating Instructions of vehicle system
tester
Test of vehicle systems HELP

K wire not switching to earth
Test of vehicle systems HELP

K wire not switching to positive Note:
Operate the vehicle system tester on the basis
of the readout in the display.
Test of vehicle systems HELP K Readout in display:

Enter address word XX
- Enter address word 01 for Engine electron-
ics and confirm the entry with the key Q.
Edition 12.00 ------------ ------------

S00.5111.54.20
, 1
! OCTAVIA
038906018BQ 1.9 l R4 EDC G00SG 2112 → K The control unit identification appears in the dis-
Coding 00002 WSC 01234 play, e.g.:
♦ 038906018BQ Part no. of control unit part1)

♦ 1.9 l Engine displacement
♦ R4 Engine displacement ver-
sion (4 cyl. in-line engine)
♦ EDC Injection system (Electronic
Diesel Control)
♦ G or no Vehicle with or without
display cruise control system
♦ 00 Control unit mapping
♦ MG Manual gearbox
AG Automatic gearbox
♦ 2112 Data status (software ver-
sion) 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
+

(
/@ '

!%

038906018B 1002 ä 08.97
038906018BC 1822 ä 08.98
038906018BQ 2112 08.98 ä 04.99
038906018GM 2162 05.99 ä 07.00
038906012F 3313 08.00 ä
038906012H 3315 08.00 ä
038906012HA 4922 08.03 ä
1) For current control unit version - spare parts
catalogue
Notes:

⇒

♦

!
♦
"
♦

------------ 01-4 ------------- % ,,-

S00.5111.55.20
♦ 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:
- Check coding of engine control unit ⇒ page

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

Select function XX
- For further procedure ⇒ Repair descriptions.
Interrogating and erasing fault

memory

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 con-
trol unit (address word 01). Engine should
be idling for this step.
(Connecting vehicle system tester and se-
lecting engine electronics control unit ⇒ page
01-2).
Only if the engine does not start:
- Switch ignition on.

Select function XX
- Enter 02 for the function Interrogate fault
memory and confirm the entry with the key
Q.
X faults recognized! K The number of stored faults or No fault recog-

nized! appears in the display.
If no fault is stored:
- Press → key.

Select function XX
- Enter 06 for the function End output and
confirm entry with the key Q.
Edition 12.00 ------------ 01-9

01-5 ------------
S00.5111.54.20
01 Self-Diagnosis OCTAV1A
If one or several faults are stored:
- → Press key.
→ K Read-out of fault number on display, e.g.:

Fault number: 00542
- → Press key.
Needle lift sender -G80 → K Fault source and fault type appear in the dis-
Short-circuit to earth play, e.g.:
- → Press key.
The stored faults are displayed in sequence.
- → Press key.
Vehicle system test HELP K Read-out on display:

Select function XX
- 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 instal-
lation operations, faults, such as connectors
unplugged, may also be detected by other con-
trol units. This is why, when the work is con-
cluded, 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 Auto-

matic 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 subse-
quently erased.
For vehicles 08.03 ä

Whenever the fault memory is erased, it is nec-
essary to generate a readiness code ⇒ page
01-26.
- Connect vehicle system tester -V.A.G 1552-

and select the engine electronics control unit
(address word 01). The engine must be run-
ning in idle.
(Connect vehicle system and select engine
electronics control unit ⇒ page 01-2).
------------ 01-6 ------------- Edition 01.04

S00.5111.56.20
OCTAVIA Self-Diagnosis 01

Select function XX
- Press the keys 0 and 2 for the function „In-
terrogate fault memory“ and confirm the en-
try with the key Q.
X faults recognized K The number of stored faults appears in the dis-

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

other.
Test of vehicle systems HELP K After the stored faults have been displayed, the
Select function XX following readout appears:
- Press the keys 0 and 5 for the function „Erase

fault memory“ and confirm the entry with the
key Q.
Test of vehicle systems → K Readout in display:

Fault memory is erased
Note:
If you have switched off the ignition between
„Interrogating fault memory“ and „Erasing fault
memory“, the fault memory is not erased.
- Press the → key.
- Press the keys 0 and 6 for the function „End

output“ and confirm the entry with the key Q.
- Carry out a road test. During the road test,

once again interrogate the fault memory. No
further faults should be displayed.
Edition 02.99 ------------ 01-7 ------------

S00.5111.53.20
⇒
⇒⇒
, 1
! OCTAVIA
#

2
Notes:
♦ %
*+* ä
Operating instructions for vehicle system
"
"
,
tester
$
'
,
♦ "

%

♦ "
"

-
"

.

0
% 1
"2
'
, "

$

-

♦ $

.34!

♦ /,

!
⇒
*
% 93&77.
#
2 (2

(2 *) !

% '
,,7- 8,7
! %
%1&.5
Implausible sig- ♦ Bent or loose sensor ♦ Poor starting

nal washer ♦ Irregular engine running, - Remove noise insulation
♦ Distance to speed sender/ misfiring and check sensor washer
sensor rotor too great ♦ Increased idling speed
♦ Metallic swarf on engine ♦ Glow period indicator light - Check engine speed sen-
speed sender -G28 flashes sor page 23-41
♦ Line interruption of ♦ Reduced performance
screening ♦ No display on rev counter
♦ -G28 defective ♦ Engine does not start
No signal 8, ♦ -G28 defective
♦ Line interruption or short-
circuit
♦ Line interruption of
screening.
,,7 87-

%
%1&8
Short-circuit to ♦ Short-circuit to positive ♦ Poor performance - Check intake manifold

positive ♦ -G71 defective pressure page 23-26
Line interrup- 87: ♦ Line interruption or short-
tion/short-circuit circuit to earth
to earth ♦ -G71 defective
Supply voltage 877 ♦ Line interruption or short-
circuit
87 ♦ Line interruption or short- - Check sender -G71
circuit - Check intake system for
leaks page 23-27
------------ 01-8 ------------- % ,,-

S00.5111.55.20
Readout on V.A.G 1552

Fault number Possible cause of fault Possible effects Rectifying fault
old new
00522 17663
Coolant temperature
sender -G62
Short circuit to ♦ -G62 faulty ♦ Black exhaust when start- - Test coolant temperature
earth ♦ Cable has short circuit to ing sender ⇒ page 23-43
earth ♦ Engine preheater does not
operate
♦ Preglowing always oper-
ates for about 20 seconds
Open/short 17664 ♦ -G62 faulty
circuit to positive ♦ Open circuit in wiring or
cable has short circuit to
positive

00527 17568
Intake manifold tem-

perature sender -G72
Short circuit to ♦ -G72 faulty ♦ Engine preheater does not - Test intake manifold tem-
earth ♦ Cable has short circuit to operate perature sender
earth ⇒ page 23-25
short circuit to positive
00532 18008
Supply voltage
Implausible signal ♦ Control unit was con- - Erase fault memory and
nected when ignition on continue checking vehicle
as appropriate ♦ Open circuit in wiring or ♦ Engine does not start - Test voltage supply of die-
short circuit ♦ Engine stops sel direct injection system
Voltage supply tml. control unit ⇒ page 23-38
15 ♦ Voltage not present when - Test voltage supply of ter-
ignition on (terminal 15) minal 15
Voltage too low ⇒ Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
♦ Diesel direct injection sys- - Replace control unit
tem control unit -J248 ⇒ page 23-20
faulty
♦ Voltage supply relay termi- - Test voltage supply of die-
nal 30 (J322) faulty sel direct injection system
control unit ⇒ page 23-38
Edition 02.99 ------------ ------------

S00.5111.53.20
01 Self-Diagnosis OCTAVIA

old new
00539 17570
Fuel temperature
sender -G81
Short circuit to ♦ -G81 faulty ♦ Reduced output - Test fuel temperature

earth ♦ Cable has short circuit to sender ⇒ page 23-30
earth
♦ Connector for injection ♦ Several faults stored - Check plug connection for
pump separated ♦ Engine stops injection pump
00542 17653
Needle lift sender

-G80
Short circuit to ♦ -G80 faulty ♦ Glow indicator lamp - Test needle lift sender
earth ♦ Open circuit in wiring or flashes ⇒ page 23-42
short circuit ♦ Rough engine running
♦ Reduced output
Implausible signal 17654 ♦ Fuel supply (was) inter- ♦ Fault 00550 Commence- - Check fuel system
rupted: tank has run ment of injection control
empty, feed line or filter possible
blocked, system drawing ♦ Misfiring, jerking
in air
♦ (Sporadic) open circuit in ♦ Engine stops - Check cable connection

wiring to fuel cut-off valve ♦ Misfiring and plug connection at in-
jection pump
♦ Sender plate of engine ♦ Misfiring at exactly - Take off oil pan and in-
speed sender bent or 3000 rpm spect sender plate
loose
♦ -G80 faulty ♦ Misfiring, jerking (particu- - Replace needle lift sender

larly at high revs)
♦ Injection pump faulty ♦ Fault 01268 quantity ad- - Replace injection pump
juster control difference
stored
♦ Irregular engine running,
misfiring
♦ No throttle response after
overrun
Open/short 17655 ♦ -G80 faulty ♦ Glow indicator lamp - Test needle lift sender
circuit to positive ♦ Sporadic open circuit in flashes ⇒ page 23-42
wiring (cable break) ♦ Misfiring, jerking
♦ Reduced output
------------ 01-10 ------------ Edition 02.99

S00.5111.53.20

old new
00545 -
Engine/gearbox elec-
trical connection 1)
♦ Open circuit in wiring or ♦ Hard gearshifts - Test signals from/to auto-

short circuit matic gearbox
A - Signal for gearshift
00550 17656
Commencement of
injection control
Control difference ♦ Commencement of deliv- ♦ Poor performance at - Test and set commence-
ery not o.k. higher revs ment of injection
♦ Engine difficult to start ⇒ page 23-13
♦ Adjustment travel of injec- ♦ Poor performance at - Test injection timing con-
tion pump blocked (dirt, higher revs trol range ⇒ page 23-28
swarf)
♦ Engine was stalled (within - Erase fault memory, con-
the last 50 starts) tinue checking vehicle
♦ Fuel feed (was) inter- ♦ Fault 00542 Needle lift - Check fuel system
rupted: tank has run sender implausible signal
empty, feed line or filter may be stored
blocked, system drawing
in air
♦ Open circuit in wiring to ♦ Engine clatters when id- - Test commencement of
commencement of injec- ling as commencement of injection valve
tion valve -N108 injection constantly ”ad- ⇒ page 23-29
vanced”
♦ Several faults may be - Test fuse
stored
♦ Commencement of injec- ♦ No constant commence- - Replace commencement
tion valve -N108 worn ment of injection possible of injection valve
at ”Basic setting” (display
block 2 varies over more
than 10 readouts)
♦ Irregular engine running,
poor performance
1) Not available at present.
Edition 02.99 ------------ 01-11 ------------

S00.5111.53.20

old new
00553 16485
Air mass meter -G70
Implausible signal ♦ Engine was stalled (within - Erase fault memory, con-
the last 50 starts) tinue checking vehicle
♦ Battery weak ♦ Poor performance - Test battery
♦ Air mass constantly indi-
cated in measured value
block
♦ Sporadic open circuit in ♦ Misfiring, jerking - Test needle lift sender
wiring (cable break) to ♦ Fault 00542 Needle lift ⇒ page 23-42
needle lift sender -G80 sender implausible signal
possible or open/short cir-
cuit to positive

♦ Air filter blocked ♦ Irregular idling, poor per- - Inspect intake system
♦ Vacuum hoses of exhaust formance - Inspect vacuum hoses
gas recirculation incor- ⇒ page 23-37
rectly connected or me-
chanical EGR valve con-
stantly open
♦ Air mass meter faulty ♦ Poor performance, jerking - Test air mass meter
⇒ page 23-35
Open/short 17552 ♦ -G70 faulty ♦ Reduced output
circuit to earth ♦ Open circuit in wiring or ♦ Black exhaust possible
short circuit to earth when accelerating from
low revs
Short circuit to posi- 17553 ♦ -G70 faulty
tive ♦ Open circuit in wiring or
Supply voltage 17554 ♦ Open circuit in wiring or
short circuit
00575 17958
Intake manifold pres-

sure
Control difference ♦ Hoses wrongly connected, ♦ Sudden drop in power - Test charge pressure
not fitted on, blocked, ♦ Reduced output ⇒ page 23-22
if appropriate leaking - Inspect charge pressure
♦ Turbocharger vacuum unit hoses ⇒ page 23-27
Charge pressure faulty
Control difference ♦ Charge pressure control
solenoid valve -N75 faulty
------------ ------------ Edition 02.99

S00.5111.53.20
OCTAVIA 1
!
⇒⇒ ,
⇒⇒
*
% 93&77.
#
2 (2

(2 *) !

% '
,,.7 557
%!

Implausible sig- ♦ Line interruption between ♦ CCS not operational - Check speed signal
nal speedometer sender -G22 ♦ Air conditioning not opera- page 23-52
and dash panel insert tional - Check speedometer
If necessary ♦ -G22 defective ♦ Possible load alteration sender
♦ Speedometer -G21 defec- shock Electrical System; Repair
9 %!1 tive Group 90

♦ Line interruption between
Implausible sig- dash panel insert and en-
nal gine control unit
9 %!1 8:5

Signal too great
,,. 5,.:
&' %'
1
!
1A.
Short-circuit to ♦ Short-circuit to positive ♦ Glow period warning lamp

positive not operational
Line interrup- 5,.7 ♦ Line interruption ♦ Glow period warning lamp - Check glow period warn-
tion/short-circuit ♦ Bulb defective not operational ing lamp page 28-2
to earth
♦ Short-circuit to earth ♦ Glow period warning lamp
lights up constantly
,,5 5,,
= 2
%
!"

-,
Implausible sig- ♦ Diesel direct injection sys- ♦ Engine does not start - Test voltage supply for die-
nal tem relay -J322 jams (safety deactivation) sel direct injection system
page 23-38
,,8 1
/
)'
1 :7
Undefined ♦ E45 defective ♦ Cruise control system not - Check cruise control sys-
switch status ♦ Line interruption or short- operational tem page 23-55
circuit - Reading measured value
block 6 page 01-35
% ,,- ------------ 01-13 -------------

S00.5111.55.20

old new
00741 -
Brake pedal monitor-

ing
Implausible signal ♦ Switch incorrectly set ♦ Preglow indicator lamp - Test -F and -F47 and set
♦ Open circuit in wiring flashes ⇒ page 23-44
♦ -F or -F47 faulty
♦ Fuse faulty ♦ Fuse or brake light faulty - Test fuse and brake light
♦ Both brake lights faulty
00765 17762
Modulating piston
movement sender
-G149
♦ 10-pin connector for injec- ♦ Several faults stored - Inspect plug connection
tion pump separated ♦ Engine stops of injection pump
♦ Injection pump faulty ♦ Drivability problems - Test modulating piston
♦ Open circuit in wiring or ♦ Engine stops movement sender
short circuit ⇒ page 23-45
00777 18039
Accelerator pedal po-

sition sender -G79
Signal too large ♦ Open circuit in wiring ♦ Speed governed to approx. - Test accelerator pedal po-
♦ -G79 faulty (idling switch) 1100 rpm as safety meas- sition sender
ure ⇒ page 23-47
Voltage supply 18040 ♦ Open circuit in wiring or ♦ No throttle response
short circuit ♦ Preglow indicator light
flashes
Implausible signal 18047 ♦ Open circuit in wiring ♦ Fast idling speed
as appropriate ♦ -G79 faulty (idling switch)
Accelerator pedal po-

sition sender 1/2
-G79+-G185 1)
Implausible signal
Short circuit to posi- - ♦ Short circuit to positive
tive ♦ -G79 faulty
01044 18020
Engine control unit

incorrectly coded
♦ Invalid control unit coding ♦ Preglow indicator light - Code control unit
flashes ⇒ page 01-23
1) Incorrect fault text readout. The correct readout is:

Accelerator pedal position sender -G79
------------ 01-14 ------------ Edition 02.99

S00.5111.53.20
OCTAVIA
%
*
% 93&77.
,8
,5,
#
2
+
%!

!
#
Implausible sig-
nal
!
%1
! 1

1

Short-circuit to
positive
,-
'
8
:,
control unit -J248-
1
!
(2

♦ Line interruption between

AC generator and diesel
direct injection system
♦ AC generator defective
♦ Voltage regulator on AC
generator defective
♦ Short-circuit in the wiring

(2
♦ Auxiliary heater not opera-

tional
♦ Reduced vehicle accelera-

tion, when the air conditio-
ning system is switched on
⇒⇒
⇒⇒
*) !

- Check wiring Binder:

Current Flow Diagrams,
Electrical Fault Finding
and Fitting locations
- Check AC generator Re-
pair Group 27; AC genera-
tor
- Reading measured value
block, display group 016
page 01-37
- Testing signals from/to the

air conditioning system
page 23-49.
,
+'

)1B-7
Line interruption ♦ Line interruption ♦ Engine preheating not op- - Check wiring
or short-circuit erational Binder: Current Flow Dia-
to earth grams, Electrical Fault
Finding and Fitting loca-
tions
♦ Low heat output relay ♦ Engine preheating is on - Check low heat output re-
-J359 defective lay page 01-18, Actua-
tor diagnosis
♦ Short-circuit to earth
Short-circuit to :7 ♦ Short-circuit to positive ♦ Engine preheating not op-
positive erational
% ,,- ------------ 01-15 -------------

S00.5111.55.20

old new
01194 19462
High heat output

relay -J360
Line interruption ♦ Line interruption ♦ Engine preheating not op- - Check wiring
or short-circuit erational ⇒ Binder: Current Flow Dia-
to earth grams, Electrical Fault
Finding and Fitting Loca-
tions
♦ High heat output relay ♦ Engine preheating is on - Check high heat output re-
-J360 defective lay ⇒ page 01-18, Actua-
tor diagnosis
♦ Short-circuit to earth
Short-circuit to 19461 ♦ Short-circuit to positive ♦ Engine preheating not op-

positive erational
01237 17945
Fuel shut-off
valve -N109
Mechanical fault ♦ -N109 defective, leaking ♦ Reduced performance - Check -N109 ⇒ page
or jammed ♦ Engine stoppage 01-18, Actuator diagnosis
or - Check wiring
Malfunction ⇒ Binder: Current Flow Dia-
Line interrup- 17946 ♦ -N109 defective ♦ Engine stoppage grams, Electrical Fault
tion/short-circuit ♦ Line interruption or short- Finding and Fitting Loca-
to earth circuit to earth tions
01262 17954
Charge pressure
solenoid valve
-N75
Short-circuit to ♦ Short-circuit to positive ♦ Reduced performance - Check charge pressure

positive ♦ Charge pressure too low solenoid valve ⇒ page
23-24
Short-circuit to 17955 ♦ Short-circuit to earth ♦ Reduced performance
earth ♦ Charge pressure too high
Line interrup- 17957 ♦ Line interruption ♦ Reduced performance
tion/short-circuit ♦ Solenoid valve defective ♦ Charge pressure too low
to earth
------------ 01-16 ------------- Edition 01.04

S00.5111.56.20
OCTAV1A Self-Diagnosis 01

old new
01265 17810
Exhaust gas
recirculation valve
-N18
Short-circuit to ♦ Short-circuit to positive ♦ No exhaust gas

positive recirculation
Line interrup- 17849 ♦ Line interruption ♦ No exhaust gas - Check exhaust gas recir-
tion/short-circuit ♦ Solenoid valve defective recirculation culation valve -N18
to earth ⇒ page 23-24
♦ Short-circuit to earth ♦ Too much exhaust gas
recirculation
♦ Reduced performance,
black smoke
01266 18026
Glow plug relay

-J52
Short-circuit to ♦ Short-circuit to positive ♦ Glow plug system not op- - Check glow plug relay
positive erational -J52
Line interrup- 18027 ♦ Line interruption ♦ Glow plug system not op- ⇒ Binder: Current Flow Dia-
tion/short-circuit ♦ Relay defective erational grams, Electrical Fault
to earth Finding and Fitting Loca-
tions
♦ Short-circuit to earth ♦ Glow plug system not op-
erational
01268 17969
Metering adjuster
-N146
Control differ- ♦ Injection pump defective, ♦ Incorrect driving behaviour - Check metering adjuster
ence (deviation) leaking ♦ Engine stoppage -N146 ⇒ page 23-45
♦ Line interruption or short- - Replace injection pump
circuit ⇒ page 23-8
upper limit value 17970 ♦ Metering mechanism ad- ♦ Jerking, poor performance
justed
lower limit value 17971 ♦ Metering mechanism ad- ♦ Black smoke
justed ♦ Irregular engine running
Edition 01.04 ------------ 01-17 -------------

S00.5111.56.20

old new
01269 17659
Commencement
of injection valve
-N108
Short-circuit to ♦ Short-circuit to positive ♦ Engine jerks when idling

positive because commencement
of injection is constantly
adjusted to advance.
Line interrup- 17660 ♦ Valve defective ♦ Engine jerks when idling - Check commencement of
tion/short-circuit because commencement injection valve
to earth of injection is constantly ⇒ page 23-29
adjusted to advance.
♦ Line interruption (fuse) ♦ Possible that several faults - Check fuse
are stored
♦ Short-circuit to earth ♦ Poor performance be- - Check commencement of
cause commencement of injection valve
injection is constantly ad- ⇒ page 23-29
justed to late
For vehicles 19561
08.97 ä
01282
Variable intake
manifold flap
change-over
valve -N239
Line interrup- ♦ Line interruption ♦ Hard engine knock - Check Variable intake ma-
tion/short-circuit ♦ Variable intake manifold nifold flap change-over
to earth flap change-over valve valve -N239 ⇒ page 23-57
defective
Short-circuit to 19560 ♦ Short-circuit to positive
positive
------------ 01-17.1 ------------- Edition 01.04

S00.5111.56.20

old new
16500 -
Coolant tempera-
ture sender -G62
Implausible sig- ♦ Sender for coolant tem- ♦ Cold-start difficulties at - Reading measured value
nal perature -G62 supplies very low temperatures block, display group 007
implausible signal caused ♦ Poor driveability during ⇒ page 01-51
by loose contact or corro- warm-up - Check -G62 ⇒ page 23-43
sion due to humidity in the ♦ Increase in fuel consump-
connector tion
♦ Increased emission levels
♦ Signal input in engine - Replacing engine control

control unit defective unit ⇒ page 23-20
(control unit defective
♦ Coolant regulator defec- - Check coolant regulator

tive (thermostat) ⇒ 1.9 l/66 kW (TDI) Engine,
Mechanical Components;
Repair Group 19
16955 -
Brake light switch

-F
Implausible sig- ♦ Brake light defective ♦ Brake light does not light - Check brake light switch
nal ♦ Line interruption or short- up and brake pedal switch
circuit to positive or earth ♦ Engine speed fluctuations ⇒ page 23-44
between brake light switch during braking
and engine control unit
17811 -
Exhaust gas ♦ Exhaust gas recirculation ♦ Exhaust gas recirculation - Check exhaust gas
recirculation sys- valve -N18- defective system not operational recirculation solenoid
tem valve ⇒ page 01-18,
Actuator diagnosis
Control devia- ♦ Exhaust gas recirculation ♦ Mixture adaptation not op- - Check exhaust gas
tion potentiometer -G212- de- erational recirculation valve
fective ⇒1.9 l/66 kW (TDI) En-
gine, Mechanical Compo-
nents; Repair Group 26
Edition 01.04 ------------ 01-17.2 -------------

S00.5111.56.20

old new
17931 -
Crash signal of
airbag CU
Implausible sig- ♦ Fault in airbag system ♦ Airbag warning light comes - Check airbag
nal on ⇒ Body Work; Repair Group
01
17964 -
Charge pressure
control
Regulating limit ♦ Fault in charge pressure ♦ Incorrect driving behaviour - Check charge pressure
not reached control ♦ Reduced performance control solenoid valve
♦ -N75 defective -N75 ⇒ page 01-18,
Actuator diagnosis
- Check charge pressure
control
⇒ 1.9 l/66 kW (TDI) Engine,
Repair Group 21
17965 -
Charge pressure
control
Regulating limit ♦ Fault in charge pressure ♦ Incorrect driving behaviour - Check charge pressure
exceeded control ♦ Reduced performance control solenoid valve
♦ -N75 defective -N75 ⇒ page 01-18,
Actuator diagnosis
- Check charge pressure
control
⇒ 1.9 l/66 kW (TDI) Engine,
Repair Group 21
17977 -
Cruise control
system switch
(CCS) -E45
Implausible sig- ♦ Cruise control system ♦ Cruise control system not - Check cruise control sys-
nal switch defective operational tem ⇒ page 23-54
♦ Line interruption - Reading measured value
block 6 ⇒ page 01-35
------------ 01-17.3 ------------- Edition 01.04

S00.5111.56.20

old new
17978 -
Engine control
unit blocked
♦ Manipulation attempt ♦ Engine starts and stops - Adapt engine control unit
♦ Start attempt with an immediately to immobiliser
adapted ignition key ⇒ Binder: Electrical system;
♦ Engine control unit not Repair Group 90
adapted to immobiliser
control unit
♦ Short-circuit in communi- - Check immobiliser

cation cable ⇒ Binder: Electrical system;
♦ Fault in the immobiliser Repair Group 90
system
♦ Immobiliser control unit

defective/missing
♦ Engine control unit - Code engine control unit
wrongly coded ⇒ page 01-23
For vehicles -
08.97 ä
18034
Data bus drive
Missing mes- ♦ Databus lines to auto- ♦ Poor driveability (jerking - Check data bus ⇒ page
sage from trans- matic transmission control when changing gears, load 23-55.3
mission CU unit interrupted alteration shock etc.)
♦ Fault in the system of the - Check automatic transmis-
automatic transmission sion control unit
⇒ Binder: Automatic trans-
mission
18044 -
Data bus drive
Missing mes- ♦ Databus lines defective ♦ Incorrect driving behaviour - Check data bus ⇒ page
sage from ♦ Fault in ABS system 23-55.3
Airbag CU
18050 -
Read out fault

memory of airbag ♦ Fault in airbag system ♦ Warning light for airbag ♦ Check airbag
control unit comes on ⇒ Body Work; Repair Group
01
Edition 01.04 ------------ 01-17.4 -------------

S00.5111.56.20

old new
18058 -
Data bus drive
Missing mes- ♦ Databus lines defective ♦ Poor driveability - Check data bus ⇒ page
sage from in- ♦ Incorrect or defective 23-55.3
strument cluster dash panel insert
♦ Incorrect or defective en-
gine control unit
18061 -
Read out fault ♦ Fault in ABS control unit ♦ No vehicle dynamics control - Check ABS control unit
memory of ABS ♦ TCS not operational ⇒ Binder: Chassis; Antilock
control unit ♦ MSR not operational Brake System
18062 -
Read out fault ♦ Oil level/oil temperature ♦ Warning light for oil level - Check oil level/oil tem-
memory of instru- sender -G266 defective comes on perature sender -G266
ment cluster ⇒ Binder: Electrical System;
Repair Group 90
18065 -
Air conditioning
input/output
Short-circuit to ♦ Short circuit in wiring ♦ Reduced performance - Check air conditioning

positive compressor engagement
⇒ page 01-18, Actuator
diagnosis
18090 -
Data bus drive
Implausible sig- ♦ Databus lines to ABS con- ♦ No vehicle dynamics con- - Check data bus ⇒ page
nal from ABS trol unit interrupted trol 23-55.3
control unit ♦ TCS not operational
♦ MSR not operational
♦ Fault in ABS system - Check ABS control unit
⇒ Binder: Chassis;
Antilock Brake System
------------ 01-17.5 ------------- Edition 01.04

S00.5111.56.20

old new
For vehicles
08.97 ä
18259 18057
Data bus drive
Missing messa- ♦ Databus lines to ABS con- ♦ No vehicle dynamics con- - Check data bus ⇒ page
ge from ABS CU trol unit interrupted trol 23-55.3
♦ Fault in ABS system - Check ABS control unit
⇒ Binder: Chassis;
Antilock Brake System
For vehicles
08.97 ä
18262 18056
Data bus drive ♦ Databus lines to auto- ♦ Poor driveability - Check data bus ⇒ page
matic transmission or ABS (jerking when changing 23-55.3
control unit interrupted gears, load alteration
shock etc.)
Hardware defec- ♦ Fault in automatic trans- ♦ Mixture adaptation not op- - Check ABS control unit
tive mission or ABS system erational ⇒ Binder: Chassis; Antilock
Brake System
or - Check automatic transmis-
sion control unit
defective ⇒ Binder: Automatic trans-
mission
19458 -
Kick-down switch
F8
Implausible sig- ♦ Accelerator pedal position ♦ Shifting points for auto- - Check accelerator pedal
nal sender -G79 defective matic gearbox N.O.K. position sender -G79
⇒ page 23-47
65535 16989
17795
18048
Control unit de- ♦ Engine control unit inter- ♦ Poor driveability - Replace engine control
fective nally defective ♦ Engine stoppage unit
♦ Glow period indicator light ⇒ page 23-20
flashes
Edition 01.04 ------------ 01-17.6 -------------

S00.5111.56.20
, 1
! OCTAVIA
3
%
!
( !

%
!
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) Only for vehicles with special equipment
2) For vehicles as of 08.03.
% '

1
% !
l Vehicle at room temperature

(at least + 15 °C)
l Air conditioning switched on
l Lowest temperature and highest blower

speed preselected

"
%
%?%

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

and select engine electronics control unit
ning in idle page 01-2).

Select function XX
------------ 01-18 ------------- % ,,-

S00.5111.55.20
OCTAVIA
Test of vehicle systems

03 - Final control diagnosis
Final control diagnosis

Start of injection valve -N108
→
Q
⇒⇒
Self-Diagnosis
- Press keys 0 and 3 for the function „Final

control diagnosis“.
K Readout in display:
Confirm the entry with the key Q.
When the valve is actuated, this results in a

clearly audible change in the combustion
noise (diesel noise).
01
⇒
If no change in the combustion noise can be
heard:
- Test injection timing device control range

page 23-28.
Final control diagnosis → K Readout in display:

EGR valve -N18
The valve should click.
Note:
The clicking of the valve cannot be heard be-
cause of the engine noise and should therefore
be felt by touching.
If the valve does not click:
- Test EGR valve page 23-34.

AC compressor cut-off
What is tested is the AC compressor cut-
off.
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 approxi-
mately every 5 seconds.
If the AC compressor is not switched off:
- Test AC compressor cut-off page 23-49.
Edition 05.97 ------------ 01-19 ------------

S00.5111.51.20
⇒⇒

Fuel cut-off valve -N109
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.

Charge pressure control solenoid valve -N75
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:
- Test charge pressure control solenoid valve

page 23-24.

Glow plugs relay -J52
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 observ-
ing how the interior light becomes dimmer
and then brighter.
If the relay does not click:
- Test glow plugs relay

Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder

Glow period warning light -K29
The warning light should flash.
------------ ------------ Edition 05.97

S00.5111.51.20
OCTAVIA 1
! ,
If the warning lamp does not flash:
- Check glow period warning lamp

⇒ page 28-2.
- → Press key.
Actuator diagnosis → K Read-out on display:

Low heat output relay -J359
The relay valve must click.
- Check low heat output relay:

⇒ Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting locations.
- → Press key.

High heat output relay -J360
The relay valve must click.
- Check low high heat output relay:

Fault Finding and Fitting locations.
- → Press key.

Fault lamp
The fault lamp must flash.
If the fault lamp does not flash:
- Check fault lamp

Fault Finding and Fitting locations
- → Press key.

Select function XX
confim entry with key Q.
6
!
%
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
% ,,- ------------ 01-21 -------------

S00.5111.55.20
, 1
!
(%
⇒

"
%
%?%

V.A.G 1551/3A, 3B or 3C.
Connect vehicle system tester V.A.G 1552

ning in idle.
(Connect vehicle system tester and select
OCTAVIA
⇒
engine electronics control unit page 01-2).

Select function XX
- Enter 04 for the function Basic setting and
Basic setting HELP K Read-out on display:

Enter display group number XXX
- Enter 000 and confirm entry with the key Q.
System in Basic setting 0 → K Read-out on display:

1 2 3 4 5 6 7 8 9 10 (1... 10 = Display fields)

)! ,,, %'
! "

2'D57E/
$

" "" " $"" "
5(*! "

System in Basic setting 0 → K Read-out on display:
42 46 0 20 90 201 64 153 127 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 ä 07.97 = 41...44

For vehicles 08.97 ä = 42...45
For vehicles 05.99 ä = 43...46
------------ 01-22 ------------- % ,,-

S00.5111.55.20
Coding control unit

If the code which is displayed does not match
the vehicle, or if the control unit has been re-
placed, it is then necessary to code the control
unit as follows.

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

and select engine electronics control unit (ad-
dress word 01). The ignition must be swit-
ched on for this step ⇒ page 01-2.

Select function XX
- Enter 07 for the function Code control unit
and confirm the entry with the key Q.
Code control unit Q K Readout in display:

Enter code number XXXXX (0-32000)
- Enter the relevant code number for this ve-
hicle and confirm the entry with the key Q.
Coding control units
Models ä 07.97 Models 08.97 ä

Code Models fitted with Code Models fitted with
number number
00001 Automatic gearbox 00001 Automatic gearbox

00002 Manual gearbox 00002 Manual gearbox with activated CAN
databus (models with ABS)
00003 Manual gearbox for 4x4 models
00005 Manual gearbox without CAN databus
(models without ABS)
038906018.. 1.9l R4 EDC G00SG 1822 → K The control unit identification is shown in the
Coding 00002 WSC 01234 display (example):
- Switch ignition off and on again.
Notes:
♦ The code entered is activated when the igni-
tion 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.
- Press → key.
Edition 12.00 ------------ 01-23 ------------

S00.5111.54.20
Vehicle system test HELP K Read-out on display

Select function XX
Readiness code
Valid for vehicles 08.03 ä
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 sys-
tem), 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 oper-
ate properly. If a fault is detected during diagno-
sis, 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 ac-

tivate the diagnostic functions such as diagno-
sis of fuel supply, diagnosis of other systems
etc.
Procedure
♦ Vehicle system tester -V.A.G 1552- with ca-

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

and enter address word 01 Engine electron-
ics, ignition switched on ⇒ page 01-24.
------------ 01-24 ------------- Edition 01.04

S00.5111.56.20
- Read function 08 Reading measured value

block and select display group 017.
Reading measured value block 17 → K Read-out on display

00000000 00000110 10000000 00000000
Meaning of 8-digit numerical block for readiness code in display field 2

1 2 3 4 5 6 7 8 Meaning
0 Ignore
1 Ignore
1 Ignore
0 Ignore
0 Ignore
0 Diagnosis of other systems
0 Diagnosis of fuel supply
0 Ignore
Meaning of 8-digit numerical block for readiness code in display field 4

1 2 3 4 5 6 7 8 Meaning
0 Ignore
0 Ignore
0 Ignore
0 Ignore
0 Ignore
0 Ignore
0 Ignore
0 Diagnosis of exhaust gas recirculation system
Edition 01.04 ------------ 01-25 -------------

S00.5111.56.20
- If the specified values are not reached, gen-

erate 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

ble -V.A.G 1551/3, 3A, 3B or 3C-
Test 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 ⇒ dis-

play group 007, display field 3
l Coolant temperature at least 83 °C ⇒ dis-

play group 007, display field 4
Procedure

and enter address word 01 Engine electron-
ics, ignition switched on ⇒ page 01-2.
Note:
Certain steps must be carried out twice, in or-
der to achieve the readiness code.
Work step 1: Interrogating fault memory
- Enter function 02 Interrogating fault me-

mory and confirm entry with key Q.
X fault detected → K The number of stored faults or No fault de-

tected appears in the display.
If a fault is stored:

⇒ page 01-8.
- → Press.
------------ 01-26 ------------- Edition 01.04

S00.5111.56.20
Work step 2: Erasing fault memory
Vehicle system test → K- Enter function 05 Erasing fault memory and

Fault memory is erased confirm entry with key Q.
Note:
Readiness code is erased each time the fault
memory is erased.
If the ignition is switched off during Interrogat-
ing 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 di-
agnoses the slowing down of the control unit
must be ended. Otherwise readiness code can-
not be generated.
Work step 4: Switching on ignition
Charge pressure sender is adapted with atmos-

pheric charge pressure sender.
Work step 5: 1st test of fuel supply and

other systems
- Start engine.
- Select function Reading measured value

block and display group 001.
Reading measured value block 1 K- For 5 seconds increase the engine speed to
2500/rpm
→
4.6 mg/h 2.0 °CA 94.2 °C 2500 rpm and then run engine at idling
speed.
Work step 6: 1st test of exhaust gas recir-

culation
Reading measured value block 1 K- Increase engine speed to 1600 rpm up to

1650/rpm
→
4.1 mg/h 4.0 °CA 93.2 °C 1700 rpm and maintain it for at least 10 sec-
onds in this range.
In this speed range, the exhaust gas recircula-

tion is active and the control difference is
checked. (Condition for readiness code to gen-
erate exhaust gas recirculation).
Edition 01.04 ------------ 01-27 -------------

S00.5111.56.20
Work step 7: Switching off ignition
Work step 8: Switching on ignition
- Wait at least 10 seconds with ignition ON.
Work step 9: 2nd test of fuel supply and

other systems
- Start engine.
- Select function Reading measured value

block and display group 001.
Reading measured value block 1 K- For 5 seconds increase the engine speed to
2500/rpm
→
4.6 mg/h 2.0 °CA 94.2 °C 2500 rpm and then run engine at idling
speed.
Work step 10: 2nd test of exhaust gas recir-

culation
Reading measured value block 1 K- Increase engine speed to 1600 rpm up to

1650/rpm
→
4.1 mg/h 2.0 °CA 93.2 °C 1700 rpm and maintain it for at least 10 sec-
onds in this range.
- Press C.
- Enter 017 for display group 017 and read

readiness code.
Reading measured value block 17 K Specified value in display field 2:

00000000
→
00000000 00000110 10000000 00000110
Specified value in display field 4:

000000000
- → Press.
- If the specified values are not reached, re-

peat procedure for generating readiness
code ⇒ page 01-26.
------------ 01-28 ------------- Edition 01.04

S00.5111.56.20
Work step 11: Interrogating fault memory
- Enter function 02 Interrogating fault me-

mory and confirm entry with key Q.
X fault detected! → K The number of stored faults or No fault de-

tected appears in the display.
If a fault is stored:

⇒ page 01-8 and re-generate the readiness
code ⇒ page 01-26.
- → Press.
Reading measured value block 17 K Readiness code was successfully generated, if

00000110 00000000
→
00000000 10000000 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.
Edition 01.04 ------------ 01-28.1 -------------

S00.5111.56.20
, 1
! OCTAVIA

%
2
*
% !
%
2
%
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

"
%
%?%

ble -V.A.G 1551/3, 3A, 3B or 3C-.
(%

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

Select function XX
- Enter 08 for the function Read measured
value block and confirm entry with the key
Q.
Reading measured value block HELP K Read-out on display:

Enter display group number XXX
- Enter the desired display group number and
Note:
1
"
,"

'
Reading measured value block 0 → K Read-out on display, e.g.:

1 2 3 4 5 6 7 8 9 10
- → Press key.

Select function XX
- Enter 06 for the function End output and
------------ 01-28.2 ------------- % ,,-

S00.5111.55.20
OCTAVIA
42 50 0 20 90
⇒
⇒⇒
Specified readouts for general vehicle check
201 64 153
0
127
Charge pressure: ignore

Injected quantity: 10...30 o.k.
♦ if not within tolerance
Commencement of injection: 20...60 o.k.
Idling speed: 41...44 o.k.
Self-diagnosis
Display group 000, engine idling (engine warm, coolant temperature not less than +85 °C)
for models ä 07.97
Read measured value block →

83
K Readout in display
Inducted air mass 70...110 o.k.

Fuel temperature: no specification
page 01-38, display group 001

Intake manifold temperature: no specification

Coolant temperature: 80...51 o.k.
♦ > 80: warm up engine
Ambient air pressure: no specification
01
Edition 12.00 ------------ 01-29 ------------

S00.5111.54.20
01
*123
+4<5*6 '

"
">8?)$

@
A

,
-

'

/
!

C>D=⇒6 (

.
)
$

!
0/&
#

⇒

)

Read measured value block

42 50 0

"

#

%

!

#

4578E9:C;<=C<6

>8F

?4 ⇒
@

CEDGA7B3
5 20

945:;<8E=H7>5B
♦
90
not
201 64
1
153
♦
air
tolerance
0
127
Self-diagnosis
for models 08.97 ä 04.99
Intake
→
83
up
Inducted air mass

♦ not
display
tolerance
001
display
OCTAVIA
003

pedal 0
♦ not tolerance display 004
♦ not tolerance display 002
measured values apply recirculation system is recirculation

is in speed about 2 minutes; necessary blip or
------------ ------------ Edition 12.00

S00.5111.54.20
OCTAVIA
for models 05.99 ä

43
1)
50 0 20 90
⇒
⇒⇒
201 64 153

Commencement of injection: 12...75 o.k.
Idling speed: 43...46 o.k.
0
127
Self-diagnosis
→
83
Inducted air mass 1) 69...110 o.k.

Fuel temperature: 91...201
Intake manifold temperature: 190...80
Ambient air pressure: ignore
Charge pressure: ignore
Injected quantity: 15...45 o.k.

The measured values apply when the exhaust gas recirculation system is switched on. The exhaust gas recirculation
01
is switched off in the idling speed range after about 2 minutes; if necessary briefly blip throttle or re-start engine.
Edition 12.00 ------------ 01-31 ------------

S00.5111.54.20
01
→
⇒
⇒⇒
⇒
♦ Accelerate the vehicle at full throttle for the test.
64 138 175
Self-diagnosis
Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +85 °C)
for models ä 07.97
Notes:
♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person
required).
Read measured value block 0

186 225 255 186 186 201 233
Ambient air pressure: ignore

Charge pressure: 171...191 o.k.
Inducted air mass: > 210 o.k.

♦ < 210 page 01-55, display group 010
Fuel temperature: no specification
Intake manifold temperature: no specification

Injected quantity: 170...195 (full load injected quantity) o.k.
♦ 125: emergency injected quantity, system fault detected
Accelerator pedal: 255 (depressed fully)
Commencement of injection: 180...245 (dependent on engine speed)
♦ if not within tolerance page 01-42, Display group 004
OCTAVIA
page 01-5, Interrogating fault memory
Engine speed: 160...190 (do not exceed 4000 rpm, engine speed is governed)
------------ 01-32 ------------ Edition 12.00

S00.5111.54.20

"
#

(
!
%

⇒

!

$
%
&

→

⇒

⇒

⇒

'

!

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 ä 04.99
Notes:
required).
Read measured value block 0 K Readout in display

205 255 201 175 255
Inducted air mass: 255
♦ 255 display 010
temperature:
Intake manifold temperature:
Coolant temperature:
♦ up
air pressure:
pressure:
♦ if not tolerance display 011
Injected quantity: (full load injected quantity)
♦ 125: injected quantity system fault detected fault memory
pedal: 255 (depressed fully)
Commencement of injection: (dependent on speed)
♦ if not tolerance Display
speed:
Edition 12.00 ------------ 01-33 ------------

S00.5111.54.20

;D

?

<
@
(
0
)

=
9

*
:!
>62
+
(
0
9
7
8
.
#
4
⇒→
3
*
1

-
)
':
5%
+
;+

-
(
)
*
,
⇒
'
5
4
!
!
#

$
"

0
1
,
/$
#
"
.
)
0
1
/
'

<
3:)8
A>!;#:-
*
A
B 5 #
⇒
"⇒'!+,/01*++

C
-
>
(
)
*
:
0
,
/
'
";
)
(
Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80 engine
ä
Notes:
required).

205 255 201 175 255
Inducted air mass: 255
♦ 255 display 010
temperature:
Intake manifold temperature:
Coolant temperature:
up

♦
air pressure:
pressure:
♦ if not tolerance display 011
Injected quantity: (full load injected quantity)
♦ 125: injected quantity system fault detected fault memory
pedal: 255 (depressed fully)
Commencement of injection: (dependent on speed)
♦ if not tolerance Display
speed:
------------ ------------ Edition 12.00

S00.5111.54.20

3
2

456
2
.3
%7@
1456
78 9

A8
,-
:

D[

;BE
<C9 /4=
+

0

J;.P-KL
FG
H+ I

>
?
3
MCAN '<
JQO
HR

<\
⇒
.?"
3
@%
I
(
$
DG

*
&
#
U
-56T>
/S E
%]
+)
F⇒
G
H
I
?
.^
s"
K
J
L
M

P3

#
/
S
$
*
-

X %

&

K
O
J
C
G
W
V
&_àr<bL
5z 6

> Y
Z
#
95
? =

OCTAVIA 01
c̀
hc
d f
g ij
Self-diagnosis
e{tàpbwt̀m
k
l]
Display group ignition on
u
v no
qaxyrji
p
Read measured value block → K Readout in display
state able
state able
pedal monitor able
pedal
Display state of pedal and state of pedal display

2 pedal positions = 1
pedal and brake pedal not depressed

pedal depressed closed
pedal depressed pedal pedal opened
pedal depressed pedal opened
pedal and brake pedal depressed
operating state of (CCS)
Cruise Display 3
to
operated
point
pedal depressed
pedal depressed
Edition 12.00 ------------ ------------

S00.5111.54.20

01
2 5 5

0
1
state
state
Self-diagnosis
Model fitted with CCS - CCS switched off

Model fitted with CCS - CCS switched on
Model without CCS, CCS function is not acti-
vated in engine control unit
OCTAVIA

------------ ------------ Edition 12.00
S00.5111.54.20
OCTAVIA
Display group 016, engine idling
x
70.0 %
x x
10000001
x x
1
1
x x
1
x
1
00
16 →
13.8 V
⇒
Self-diagnosis
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

page 01-37, Table 2
page 01-37, Table 1
Auxiliary heater switched off because:
Coolant temperature greater than 70...80 °C1) or intake air temperature

greater than 5 °C
Alternator faulty
Battery voltage less than 9 V
Models ä 07.97 - engine speed less than 800 rpm
Models 08.97 ä 04.99 - engine speed less than 875 rpm
Models 05.99 ä - engine speed less than 861 rpm
01
1 Engine start within the last 10 seconds

1 Coolant temperature sender (G62) or
intake manifold temperature sender (G72) faulty
1 Ignore
1 Ignore
1) 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
Meaning if display places = 1

x x Actuation of heating elements
1 Low heating capacity relay (J359), switched on

1 High heating capacity relay (J360), switched on
Edition 12.00 ------------ 01-37 ------------

S00.5111.54.20
01

2

5

-) .1
2
/+
$
6
'4

,
)
Specified readouts for injection pump

$
-

/2!

+
.1 "
#

,
.&

$

"
⇒
'/3 '
⇒

3
/

#
&

(

/
/ .

)*

+
!

)
0
0+!)
Self-diagnosis
for models ä 07.97
♦
♦
♦
1 →
load
K
♦
♦
cold
o.k.
o.k.
OCTAVIA

♦ o.k.
♦
♦
load
cold
♦ ä o.k.
♦ ä o.k.
♦ ä o.k.
------------ ------------ Edition 12.00

S00.5111.54.20
3

2

72
,4
+3
!4/5
"
8
#
:9,.;
6
7R 9 $ < =
>
3
BR
7/LI⇒-M&P
7Q
(
N
D

?
T
*
2
3
5
9
)
/
)
I
1
: 0
;
A
@
+
'
9
<
D
L
-
Q
R
K
.
=
6
M
'
F

C
G
5
,
N
/
&
*
⇒
S
G
+
N
)

&
'
%
0
>
3
7
9
?
K
.
F
(
4
-
,

(
,
+
-
)
*
5
3
M
N
5
O⇒
(
'F
+
)
&

'
I
P4
5
J
A
I

,
/
&
-
9
*
<
=
2
P
O
>A
>
I

7R
!789:;
V6
/5 " LI-<
09,./⇒'7( '
R
=
>
3 <
M&7Q
D

NA
?A
>
U
G3,9
+2+T )
A
@
'
90
/

B
C
5 3
<

&
'
%
0
>
3
7
9 N

(
,
+
)
-
*
5
3⇒
(F

'4
5
J

,
/
&
-
9
*
<
=
2
01
H
OCTAVIA
I
Self-diagnosis
K)*<5
L:;
I/> <
D
MU1KQ
-MF
NR P
?
,.0'
/ ⇒ N +
)
Display group engine idling t not less
++NS9)G*
& . S
G/⇒3-4,<(5
N
) -.
*
for
F 00N&M+)-,*5
' / 9
ä
Read measured value block 1 → K
O'&PAI>
♦ o.k.,
♦ o.k.
♦
♦
load
cold
♦ o.k.
♦
♦
load
cold
Display group engine idling t not less

for ä
Read measured value block 1 → K
♦ o.k.,
♦ o.k.
♦
♦
load
cold
♦ o.k.
♦
♦
load
cold
Edition 12.00 ------------ ------------

S00.5111.54.20

Z[1
01
2

\p]3
e,6f9

{5
z^4_.

`akbcvd̀Y
78+^

:ug
;
9

1
<
3
=
6
7mhi_adS
7j
/l.%TV
/37+KAv
A-]*5
*'^k:;
♦
♦
-
-
♦
♦
-
or
>
(
1
8
&
H/cr`_l,bM

2
?
@
9
4N
+P
K)
Lme%
3
→

$
5
FFo%
&
9

'
(
K⇒.pq
-
7nB^5
=
Li0KG
0&R9
Or*s(,t
*
)
5
Self-diagnosis
block
+
1
2,H
<
-
4
C>uUbcvW
A3l ) .
B/%
I
0
(
*jda/^+g
.
closed

9

,
A'
54)
H
CD
/>
+
*8 "
#
!
E
F
A
'
G
I
%
&
H
(
J
9
.
-
,
P
0
7
-,m4'e&dbacvjOwV
OCTAVIA
valve
⇒)
Jh%^k`_A)ef/aXg /
5
.*
%+
4
,
*C(^bt9
rx
y

------------ ------------ Edition 12.00
S00.5111.54.20

!!"#$

!" #
$

A$
%
&
$
'
:$
3$
:)*+(
@,!-'.=
8AG
B
*)%*!+G
/(
*&
3-F.=
+,!'
+B
! !/
@>0

)
,
-
.
#
;
B
A
G
/>0

=
/1
<
?

12$

(
)
1
0
2
%
$
>
,
8A2)*+$
3B
4

4
)- ?<.

(
⇒

)
H
9

4DE,-&⇒;A%+0
.
9
D
F E),
/-3
5
6&24;⇒?A%7F18)9
0/6
.D:,4
? +
-37&;E1A8#29
0.D:,- &
;A#
/G
-
.
%
I' (
)
1
*:3!4?<=
,+@>8:,0
2
$
" ()
34)-!?<.@/⇒8394DE,-&⇒;A%+.
3F9DE)/-6&24;⇒?A%7F18)0
0 , 5 /9. +?-37&;E1A8#20
6D:,4 9.D:,-&;A#
Read measured value block 1 → K Readout in display
readout
readout
piston movement sender at stop
♦
♦
resistance in cable connection
control pump incorrectly set replace
piston movement sender at minimum stop
♦
♦

ä
Read measured value block 1 → K Readout in display
readout
readout
piston movement sender at stop
♦
♦
piston movement sender at minimum stop
♦
♦
Edition 12.00 ------------ ------------

S00.5111.54.20

.
2

(.
<
/0+1
2.34

)
2+1
5

6
7
/
T+.
"

3
4
5
6
7
>
%
1
3
D
5
6
7
C

8
9
B
'
%
1
"
)
-
3
D
5
6
C
G
#
F
I
P
@
(
,
0
R
K
$
)
>
"
47
'
E

>
2
+
&
2
!
:
;
A
4

$
,
(
'
*
+
"
#
%
)
-
&
<
=
?
0
>
@
1
E
2
H
Q
(
%
)
"
#
+
K
⇒
S
'
*
8
L
I
C
<
>
V
$
0
U<
%
1
"
)
>
(
'
#
+
K
&
⇒
6
8
C
,
)
1
>
-
<
(
'
%
0@
<
(
'
"
>
)
%
/
L
M
O
,
'
#
0
%
I
N
*
-
$
"
)
>
1
"
)
8$
(
K
*
<
(/
0
R

3R K $
*
⇒

5
6
T
2.34
X 7
/ ./
L
8
#
K
I

4
5
6
7
2)K(*I⇒+"C
;R
2D
@$/M
*
+
#
W
-

8
9
<>3#
B
'(<K
%
1
"
)
-
30,5
D
5
6
C
G
#7

>/
!
:
8
4

$
(
,
'
"
#
%
)
*
+
&
-
=
?
0
>
M
/
9
1
E<
%
1
"
)
>
(
'<
(
@
'
%
"
>
)
01
H
Self-diagnosis OCTAVIA
F
I
P
@
(
,
0 + Q
(
%
)
"#
+
K
&
⇒
6
8
C/
L
M
O
,
'
#
0
%
I
N
*
-$
(
K
*
engine idling not less than +85 °C)
R
K & #
+
K
⇒
S
'
*,
)
1
>
-$
"
)
>
1
"
)<
ä
8
L
I
C
<
><
%
1 )
>
" ' $
V
0
U%
0
→ K
6
7
'LG2MW*⇒-S 8
4 E2/
H#%1+K
valve
♦
♦
♦ blocked
valve
♦
cold
valve
♦ o
engine idling not less than +80 °C)

ä
Read measured value block → K
valve
♦
♦
♦ blocked
valve
♦
cold
valve
♦ o
♦
cold
------------ ------------ Edition 12.00

S00.5111.54.20

'
6

7839

#
$
0^ ?
:;<=%>

& @

:7;=>
A
S1VN0B62<\ @
?
A

F38*:9
L
-
JH'0;,B=>

'
B
C
/
9
*
1
2
3
M
P
Q
K
S?

→
)
D
E
K
H
5
4
+
UA
W@ *
F
V
*+
8
N
,
-
9
<
-,2X3

.
R
:
/
G
Y

0
1
H
Z
64
2
3
J
B

5
I-
F
0
/

J
F
0
/
*
9
*
1
H
-
N
,
4
2
3
+
5
.
⇒

H
1
G
4
O
8
+
2
9
.
5⇒!
N"
=
I
/
*
1
[
0
4
18].,5H-18
for ä
Notes:
required).
Read measured value block K
valve
♦
♦ block
o.k.

♦
valve
♦ o.k.
♦ o.k.
Edition 12.00 ------------ ------------

S00.5111.54.20

8 :
9
;5=!>8?@
<

2c A
B
"
=>D?@

C

B
A
C
#$
[ &'
%U/E
<
\

(
→
)
F
1
K
,
3
-
5
4
P
>3WZ2=94585̀;,EK>2ID)
6.P?@
;/A
TB S
R G
U
.
+
H
N
Q
C
B
Z
/
,
I
9
7
8
-
;
>
<
D.
R
,

/
=
O
1
0
F
SJ
3
2
3
1
K
P
W4
56

7
L
I
/
T
M
.
-
1<
2
,
3
K
4-0I
2
1
/
6
7
⇒M
,
5
Z

K
W
J3
9
D
;U E

Y
X
]
2
-
?
O6
,
LS
13
I< Q
C
M3^KM,01EW7⇒_34a5
K21/.b
, 3 5 12-6.
UXI067M⇒;D<
Z 8 KY
/ , B
3< K 74 .
_W2X/5-9DUE
at test in not less +80 engine

ä
Notes:
required).
valve
♦
♦
valve

♦ block
valve
blocked
leaks
------------ ------------ Edition 12.00

S00.5111.54.20

567829
>
$:;5<=
?
@
;_

"
%
#
!

:
A
<0SV/:615\
=
>
?
@
8,>
;9
JW
Q?
,
1Q0X &
B
E28)BH;/FA&
F+L<= C
.M

→ D
.H;JL)N
9
)0*
H
/Z@
2
O +
(
K
M
@
?
V
,
)
6
4
5*
9
A+
)N:,-
O.
C
G
0
/
0
3-.BS84⇒[F0PJ1]2
H
S1
L

23

4
I
F
,
P
+
*
.9
/
)
0
H
1*-F
/
.
,
3
4
⇒J
)
2
V

H
S
G
0
6
A
8
QB

T
YU
/
K3
*
)
<
I
O
.0
H/.,+^
) V0
52 ./*3+
QTF-34J⇒8A9
HU
, ) ?
09 H 4 1+
[S/T,2*6AQB
Display group at full test in or gear t not less engine

ä
Notes:
required).
valve
♦
♦
valve

♦ block
valve
blocked
s leaks
Edition 12.00 ------------ ------------

S00.5111.54.20
01
Specified readouts for engine idling
1
900 rpm
1
1
0.0 %
Engine speed ⇒⇒
⇒⇒⇒
Analysis: display of engine operating state
x x x
AC signal
010 88.4 °C
Accelerator pedal position

♦ 0.0 % o.k.
→
Self-diagnosis
Coolant temperature
♦ 85...100 °C o.k.
♦ < 85 °C:
Engine operating state
warm up engine
Table of engine operating state, page 01-46
♦ > 0.0 % Accelerator pedal position sender incorrectly set or faulty

page 01-38; display group 001
Meaning if display places = 1

Engine operating state
switch off air conditioning

v o.k.: (idling speed switch closed)
Idling speed increased:
♦ if AC switched on switch off air conditioning
♦ if accelerator and brake detected test brake
page 23-47
OCTAVIA
pedal switch
♦ if coolant auxiliary heater switched on warm up
engine
------------ 01-46 ------------ Edition 12.00

S00.5111.54.20
→
for models ä 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 crank-
shaft requires a longer time for the next half crankshaft revolution. In contrast, a cylinder with a stronger perform-
ance accelerates the crankshaft to such an extent that it requires a shorter time.
♦ If the control unit has detected a variation, the cylinder in question is immediately supplied with a greater or lesser
injected quantity until the engine is again running smoothly.
♦ What is shown in the measured value block is the variation of the injected quantity of the individual cylinders in
comparison to cylinder 3, which is necessary to achieve smooth engine idling.
♦ +... mg/H: The relevant cylinder has a weaker performance than cylinder 3 and is therefore supplied with more fuel.

♦ - ... mg/H: The relevant cylinder is stronger in performance than cylinder 3 and is therefore supplied with less fuel.

0.82 mg/H -0.12 mg/H 0.49 mg/H
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
♦ -1.5 mg/H...+1.5 mg/H o.k.
♦ -1.5 mg/H...+1.5 mg/H o.k.
Edition 12.00 ------------ ------------

S00.5111.54.20
9,:#
+ ;

-<
%
$.=

'>?@
& (
! "
)A9:4AE
0G
<<:= 3
1
2
/
?9=
@
> B
C
9
?D @

4
5
→
9
<
?<:9=
=
>
AFAE
:>?@
:G =
>@

*
+
.
8
,
-
1
7

B
?>?4@
AD
:FE <
9
@
D
=
>
B
FG<4D
E
G
F55
engine idling (engine not less °C)

models ä
♦ 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 crank-
shaft requires a longer time for the next half crankshaft revolution. In contrast, a cylinder with a stronger perform-
ance 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 and is therefore supplied with more fuel.
♦ - ... The relevant cylinder is stronger in performance than cylinder and is therefore supplied with less fuel.

measured value K in display
Idling controller - injected quantity cylinder

♦ o.k.
♦ cylinder weak
♦ cylinder strong
♦ o.k.
♦ cylinder weak
♦ cylinder strong
♦ o.k.
♦ cylinder weak
♦ cylinder strong
♦ o.k.
♦ cylinder weak
♦ cylinder strong
------------ ------------ Edition 12.00

S00.5111.54.20

2

%
3
(

OCTAVIA
9

>a
4!:5;6"7<
UE=M⇒kGI
ä

$j
a
#=>?
#U9J8E
=

^8XO@d
M< %
&

?A
Si
V
K;eTSK<
E
L
W
Zh
a
Pd '
8
B
J
MV=@?
R
C
O
8
X
]^l]>\
_ 9e
engine idling

900 rpm

(
<
b)
=
D
?

>
E
F
Q
F⇒TSIZLYBA♦
♦
♦

*
&
%
(
G
;
@
C
R
gas

I
H

K
J
L
T
fM
N
F
E
⇒ G
O
P
→
Q
I
L
9
HR
Y
c+
*
K
=
Z
X
&
E
J,-
.
[
^
8
♦
/
0
;
<
9
G1>
?NT
F
S
ZX=MJQGV⇒gGFI=OiAUK=IME
8
>;OiE Self-diagnosis
air mass
t
ratio
not less
air mass in display block
air in intake area

recirculation valve
inspect intake system

recirculation
recirculation
blip
leaks
01

♦ substitute value p 0 ault memory
air mass requested by control unit
♦
♦
too cold warm up
quantity too readouts injection pump
temperature very no correction possible
speed display
Edition 12.00 ------------ ------------

S00.5111.54.20

01

models

S
"#$%

'I &'(
! )
(
%
&
?.&6E⇒B8L
4I
6?"3!.
D6T0$ @
.
E2=<>@4R)%
900 rpm

!
+
,
*
3
8
5
;
A
C
"
F
I
9UD&'(
=
!

-
B
(
%
&
GL
J
G/⇒>0M
NQ .
:'
/2

0
2
1
$
,
=
*
<
;
%
M 3

4
5
>
O
6
⇒/
.
&7 08 9": 2
NB&'630@:⇒8K2P0/!6.ETG*
"
4<:G*$;R.
5
engine idling (engine
ä
♦
♦
♦
5
4
;
>
<
K

&
B
!
0
/
G
E
"
438;$2R&?.46&25N
→
Self-diagnosis
♦
air mass
ratio
not less
air mass in display block
air in intake area
too cold
mass meter t
up
p
blip
recirculation
substitute value
°C)
recirculation valve
inspect intake system

recirculation
leaks
OCTAVIA
memory

♦
air mass requested by control unit
♦
♦
too cold up
quantity too readouts pump
temperature very no correction possible
speed display
------------ ------------ Edition 12.00

S00.5111.54.20

+

OCTAVIA

,-./0

O

#PH=4>N

!
"
0

A4BC=6+
$3+,8-1?

/@P "
!

Notes:
♦

2*

"

/0
-75G>HI
temperature

4,@-.J/0
3 %
>9=:
readout
open circuit in
&
!
7?
5ML
68F♦
(
'
"
A76+B
5
@+A<BC? >I
→

D)
3
CK2L/0 E

-4JMF?:
2
;
<
9
F
3
?
6*6
Self-diagnosis
open circuit in
temperature sender
a constant is
temperature
open circuit in
substitute value
temperature intake
a constant
coolant temperature sender
a
as a substitute value
uel temperature is s
temperature sender
is as a substitute value
as a
01

♦ 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 ap-
proximately 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

6 89
7
* $"

1
;Z =>?
:0;2<

3
C=K749S !

#B@
G=H
A6

"
68>?
(<

$
KA6
CD;E7F<
IJN

KO;\⇒=>?
Fc B 8
D

%
4
@
<
=
G
E
RQLV^S
:
→
>
?
H&
I
J

A
B
P
'
C
D
6
LE
8
S
Z!
F
<
[G
M
"

H
J
I
>
?
=
Q
T
)

K
L
R
N
;
%
B
T"
*
M
F
D
I
K
E
=

⇒
O
N
\
Ǹ%

]

F
^!

-
.
,
+
"

%
W
J
=
D
V
D
T
\
K
_
8
H

?
T;76]X@W\^DGVW_P
68<
>? aB
;RXd
@
Specified readouts for
for ä
Notes:
required).
Read measured value block K Readout in display

rpm
limit on basis detected air mass
♦
- detected air mass test air mass meter

- recirculation at load
control on basis speed
♦ speed too or too

♦ increased as a result
pedal
♦
- pedal not accelerator pedal position sender incorrectly set or
t p
speed rpm
------------ ------------ Edition 12.00

S00.5111.54.20

-Y
OCTAVIA

)*+,*-.

#1
/0
)
Display group
Notes:

2
3
0/?536+
1
0W
.
/ !
"
$

)
4
-78*F %
'
.
5C9:-,;)Z
7Q<. ?T
→
1
/
:⇒=/>01
0D?56@7I8F
DLE<

&
-9:*B-;
-G3P=
?J)>
at full

rpm
)6
2
8

9
F+
M;<
>
=
1
.
/
G
N

@
E
B

6
G
A
:
=
89
C
B
⇒
?OK,R4@Q8:;IJR,*/3Q.
OS8
QJ
:
G
?B-EKX
P01
(road test in
ä

J
>
I
/
RU;4+6V-2
<
=
. 83
)
L
K
Self-diagnosis
or gear t not less
required).
♦
- detected air mass
-
control on
limit on
basis
basis detected air mass
test air mass meter

recirculation
speed
t
engine
01

♦ speed too or too speed
pedal
♦
p
speed rpm
Edition 12.00 ------------ ------------

S00.5111.54.20

, .
-
!"

$
0\
#/-01
2
%
82B6.-I
34 061
8,5

:Z
=F0*]
234

&
)
'

(9:;<=,>?1
,
7
9
;
<
6
/
I
*
3
1
2
>
BT⇒@2A34
?
-
SEGBCLW →
4
@
MA
8
9
,
:
;
7
0
C

?
A
@
3
4
1
2
J
Q

B
C
H
E
G
0

J
9
D
=
@
;
B
<
2

F
E
⇒
UH0*J,RN7T;=>LMU,*/6T1
M
V =
;
J
R
S
?
@ >
YE0HN[
X34

M
A
2
;
L
T
B
U
1
96
,
O
N
7.
at test in not less engine

ä
Notes:
required).
Read measured value block K Readout in display

rpm
limit on basis detected air mass
♦
- detected air mass test air mass meter
- recirculation
control on basis speed

♦ speed too or too speed
pedal
♦
t p
speed rpm
------------ ------------ Edition 12.00

S00.5111.54.20

34

$5

-BO

P#.)4+$<'(-;
678
,A
>Q ,5
0$
7L=)+SF21I⇒H8
9>$D/9
#3
M

?B*5

L=3<K
$
→
#
:
'
.
N
(
6
O20L
;
B
&
<
A
⇒
/
+

)
'
(
*
1
=
$
#
'
*
-

,
+
:
>
H
,
.
@?)4=19S$
-
.
6
F

1
/
0
2
$
:
*
>
#
)
'
=
/
-
,
.
I
4
J
D
B
3
9
?
1
0
6
(
2
⇒

@
?
C
E
-
D
.
<
*
B
0
(
6
+
H

1
,
=
'
/
2
$
3
9
# !
"
F
(
+
7R 9 68 5
<=6
for ä 07.97
Notes:
required).

mbar mbar
or
mbar

♦
s less or more r
block
mass
mass
Edition 12.00 ------------ ------------

S00.5111.54.20

<=
-

>
!?" #,=-
@A

$
6K\ 5X
K_
GJ D
%[724E0 5>
,<

&
'
)

(16FBG-<8-
T
3
V
U
9
E >*
,
W
X
Y
-
C
0
7
1
?
Z
F→;
+
9
UD
KE
8

/
J
⇒
0
4
0
1
:
F
-
,2

6
5
7
3
4
C
G
?
Q
5
3
7
1
O
6
8
9
R
=
;

:
;
3
S
M
K
H
⇒

-
G
,
2
0
6
5
7
<
:
9

F
?
C
8
4I
H

L
N
6
:
M
5
7
E
3
F
0
8
;
K
-
B
9
1
?
Q
,

1
4
O
H3B24ZO:;,0
@U-?A @⇒645QA
H]IRE:B2-FZ 2-^503;
F,KQ[?6>
=
010 at test in not less engine

ä
Notes:
required).

mbar mbar
or
mbar

♦
or
block
mass
mass
♦ value
------------ ------------ Edition 12.00

S00.5111.54.20
678

3
4$5
,A

;
#4$
-BO
BT
,W
>*L69)+>R3

"

!S.)+<'$(-=78
# $
#
3
$
9
K
*
5
'
.
M
N
O
Q
=
L
5
/
0
<
:
(
6
R
-F$1?2#⇒'-,H78→2
0L;
B<
/

&
A
⇒
+'
(
1
#
'=
$)**+
:
.,
H
,
-
.
>6
F
(/
0
I
4
3
9
21
2
J
B
?
⇒D

*
)
$
>
#
'
-
,
.
1
0
=

:
/
6@
?
+

C
E
-
1
D
,
.
<
*
=
'
/
2
B
$
P
0
(
6
H
#

F
(+
?U@I<19)$=#RB4HS6)$-=5
V,'*2
Display group 010 at full test in or gear coolant t not less +80 engine
ä
Notes:
required).

mbar mbar
or
mbar

m
♦
or
block
mass
mass
♦ value
Edition 12.00 ------------ ------------

S00.5111.54.20
01
Specified readouts for charge pressure control

→⇒⇒
Self-diagnosis
Display group 011 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +85 °C)
for models ä 07.97
Notes:
required).

K
OCTAVIA
! " #

$%&
' " #
♦ " # ( ) ! **
♦ " # +
$ % " # ,#($((
♦ -
" # +
$ . " " # ,

$%&/# " # ,#($((
$ 0# " # #", " #
,#($((
1" # 2
♦ ***( **
♦ 3( " # 4#5
6#(***( **
------------ 01-58 ------------ Edition 12.00

S00.5111.54.20
<
OCTAVIA

7

',9

%
!
6

4!"$

&1 →

'

"

#
4,5+%

(#!082
,/+* )

-⇒:(,; ' )
+,&⇒2
3#4(
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 ä 04.99
Notes:
required).

♦

K

01

♦

♦

♦
♦

Edition 12.00 ------------ ------------

S00.5111.54.20

( *
)

5^
+!,-)"
;2?;Y .) #
+,
WIN@[
;+8,.( &
$F+
G
X
,
@
Q
S

A%4/

→
0
1
3
5
2
4
B
-
.
A
*
D
C
=
9
7
>
8
?
H
)
I
L
M
@
:
R
G

7
6
0
E
J
N
>
M
2

;
9
8
4
:
O
⇒
=
8
7

<
2
?
@

=
5
7
>
?
@
K
(
N
A
>
M
7
?
:
J

I
;
=
9
2
K
U
E
V
5
4
8
@
J
T

N E
2
4
T(
A ;
9
)VC=D7>?4CZ9V\2]7
>
?
H
⇒
011 at test in not less +80 engine

ä
Notes:
required).

K

♦

♦

♦

♦
♦

------------ ------------ Edition 12.00

S00.5111.54.20
OCTAVIA Fuel Preparation/Fuel Injection 23
Servicing diesel direct injec-

tion system
Safety precautions
Pay attention to the following precautions in or-
der 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 igni-
tion is switched off.
♦ To operate the engine at starting speed with-

out it actually starting, e.g. for testing the
compression pressure, unplug the connec-
tor 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 sur-

face and cover over. Do not use fluffing
cloths!
♦ Carefully cover over or seal opened compo-

nents if repairs are not carried out immedi-
ately.
♦ 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 possi-
ble.
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 ------------ 23-1 ------------

S00.5111.51.20
23 Fuel Formation / Fuel Injection OCTAVIA
Summary of fitting locations ä 07.97
Components A to E are not shown on the sum- D - Brake light switch (F) and brake pedal
mary illustration. switch (F47)
♦ Combined in a housing
A - Relay for diesel direct injection sys- ♦ In footwell at brake pedal ⇒ page
tem (J322) 23-2.1, Fig. 1
♦ Electrical centre ⇒ page 23-2.1, Fig. 1
E - Clutch pedal switch (F36)
B - Glow plug relay (J52) ♦ In footwell at clutch pedal ⇒ page
♦ Electrical centre ⇒ page 23-2.1, Fig. 1 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 Fuel Formation / Fuel Injection 23
1 - Mechanical exhaust gas recirculation 11 - Plug connection
valve ♦ 2-pin
♦ For needle lift sender (G80)
2 - Injection nozzle with needle lift sender
(G80) 12 - Plug connection
♦ 3-pin
3 - Diesel direct injection system control ♦ For engine speed sender (G28)
unit (J248)
♦ With altitude sender (F96) 13 - Plug connection
♦ 10-pin
4 - Electromagnetic EGR valve (N18) ♦ For fuel temperature sender (G81)
♦ For quantity adjuster (N146)
5 - Charge pressure control solenoid ♦ For modulating piston movement
valve (N75) sender (G149)
♦ For commencement of injection valve
6 - Air mass meter (G70) (N108)
♦ For fuel cut-off valve (N109)
7 - High heating capacity relay (J360)
♦ Only for models with optional equip- 14 - Commencement of injection valve
ment (N108)
8 - Low heating capacity relay (J359) 15 - Fuel cut-off valve (N109)

♦ Only for models with optional equip-
ment 16 - Fuel metering control of injection
pump
9 - Coolant temperature sender (G62) ♦ With fuel temperature sender
♦ With quantity adjuster (N146)
10 - Engine speed sender (G28) ♦ 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 ------------ 23-2.1 ------------

S00.5111.52.20
23 Fuel Formation/Fuel Injection OCTAVIA
Overview of fitting locations 08.97 ä 07.00

D - Brake light switch (F) and brake pedal
switch (F47)
♦
# !
A - Diesel direct injection system relay ♦ #$ ! ⇒
(J322)
♦ ⇒
E - Clutch pedal switch (F36)
B - Glow plug relay (J52) ♦ ! ⇒
♦ ⇒
C - Accelerator pedal position sender

(G79)
♦ !⇒
"
------------ 23-2.2 ------------ Edition 12.00

1 - Intake fitting 11 - Engine speed sender (G28)
♦ With mechanical exhaust gas recir-
culation valve 12 - Plug connection
♦ With intake manifold flap ♦ 2-pin
♦ For needle lift sender (G80)
2 - Intake manifold flap changeover valve
(N239) 13 - Plug connection
♦ 3-pin
3 - Injection nozzle with needle lift sender ♦ For engine speed sender (G28)
(G80)
14 - Plug connection
4 - Diesel direct injection system control ♦ 10-pin
unit (J248) ♦ For fuel temperature sender (G81)
♦ With altitude sender (F96) ♦ For quantity adjuster (N146)
♦ For modulating piston movement
5 - Electromagnetic EGR valve (N18) sender (G149)
♦ For commencement of injection valve
6 - Charge pressure control solenoid (N108)
valve (N75) ♦ For fuel cut-off valve (N109)
7 - Air mass meter (G70) 15 - Commencement of injection valve

(N108)
♦ Only for models with optional equip- 16 - Fuel cut-off valve (N109)
ment
17 - Fuel metering control of injection
9 - Low heating capacity relay (J359) pump
♦ Only for models with optional equip- ♦ With fuel temperature sender
ment ♦ With quantity adjuster (N146)
♦ With modulating piston movement
10 - Coolant temperature sender (G62) sender (G149)
18 - Intake manifold pressure sender (G71)

and intake manifold temperature
sender (G72)

switch (F47)
Edition 03.98 ------------ 23-3 ------------

S00.5111.52.20

!

"#
Overview of fitting locations 08.00 ä

light switch and brake
switch
♦
# !
direct injection ♦ #$ !
⇒
♦ ⇒
E switch
♦ !
♦ ⇒ ⇒
s ender
♦ !⇒

"
------------ 23-3.1 ------------ Edition 12.00

OCTAVIA Fuel Formation/Fuel Injection 23
1 - Mechanical exhaust gas recirculation 14 - Plug connection
valve ♦ 2-pin
♦ with intake manifold flap ♦ for needle lift sender (G80)
2 - Intake manifold flap changeover valve 15 - Plug connection

(N239) ♦ 3-pin
♦ for engine speed sender (G28)
3 - Injection nozzle with needle lift sender
(G80) 16 - Plug connection
♦ 10-pin
4 - Heated crankcase ventilation (N79) ♦ for fuel temperature sender (G81)
♦ only models with optional equipment ♦ for quantity adjuster (N146)
♦ for modulating piston movement sen-
5 - Diesel direct injection system control der (G149)
unit (J248) ♦ for commencement of injection valve
♦ with altitude sender (F96) (N108)
♦ for fuel shut-off valve (N109)
6 - Electromagnetic exhaust gas recircu-
lation valve (N18) 17 - Commencement of injection valve
(N108)
7 - Charge pressure control solenoid val-
ve (N75) 18 - Fuel shut-off valve (N109)
8 - Air mass meter (G70) 19 - Fuel metering control of injection pump

♦ with fuel temperature sender (G81)
9 - Low heating capacity relay (J359) ♦ with quantity adjuster (N146)
♦ only models with optional equipment ♦ with modulating piston movement
sender (G149)
♦ only models with optional equipment 20 - Intake manifold pressure sender (G71)
and intake manifold temperature sen-
11 - Coolant temperature sender (G62) der (G72)
12 - Vacuum unit
13 - Engine speed sender (G28)

switch (F47)
Edition 12.00 ------------ 23-3.2 ------------

S00.5111.54.20
23 Fuel Preparation/Fuel Injection OCTAVIA
Servicing injection pump
⇒ page 23-8

♦ Pay attention to safety precautions
⇒ page 23-1
♦ Pay attention to rules for cleanliness

⇒ page 23-1
♦ Removing and installing injection pump
♦ Dynamic test and setting of start of injection

⇒ page 23-13
------------ ------------
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.
1 - Stretch bolt
♦ Always replace
♦ 20 Nm + 1/4 turn (90°)
2 - Injection pump gear
3 - Hub nut
♦ On no account slacken
Edition 05.97
S00.5111.51.20

"

$

'

(

*

!

&

!
)

#

%

-

5
7
2
./01,
*

1
8
/
3
4
6 .#
+

%

13
♦ for feed line ♦ for cylinder 3 with needle lift sender
♦ 28 Nm ♦ removing and installing, testing
⇒ page 23-16
♦ tighten screw for return-flow line of
♦ replace cylinder 3 to 10 Nm
Fuel 1
♦ 20 Nm
1
♦ for return-flow line 1

♦ 28 Nm
1
♦ to control valve/fuel filter 1
10 Injection
♦ tighten to 25 Nm 20
♦ use ring wrench, e.g. 3035, for remov-
9:;<
ing injection lines 21
♦ always remove complete set of lines
22
11
♦ 45 Nm 23
12 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
3
♦ 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 tempera-
ture below +15 °C
♦ passage to filter closed at tempera-
ture above +31 °C
Edition 12.00 ------------ ------------

S00.5111.54.20
.- ##
$ OCTAVIA
1 *
!
. 1 *
♦ from injection pump
⇒
- 1 #%
♦ to injection pump
: 1 #
♦ the direction of flow is marked by ar-
rows
♦ for removing loosen clamping screw
at bracket
♦ do not mix up connections
♦ replace if damaged
♦ fill up with diesel fuel before installing
7 1 &

♦ replace if damaged
1
!
♦ 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
32)'

#ä,85
1 3
'
♦ 10 Nm
. 1 3
%
%
&8
♦ inspecting page 23-47
♦ setting page 23-7
- 1 ()
: 1 !'

7 1 ,4
1
%
!
8 1 (%
2

------------ 23-6 ------------ % ,,-

S00.5111.55.20
%(&
!"'
) #$*+%!
,+-./0
1 racket
2 p edal
♦ testing ⇒ page 23-47
3 pedal
accelerator pedal
t t and

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.
- Install sender with preassembled cable pul-

ley.

⇒ page 01-2.
Edition 12.00 ------------ ------------

S00.5111.54.20

4
6

56 ! "→

(
' !'"→10

'(
,
-

%

&

,

%
!
'&/
%

&
).
!

*
+

/

*"2''-

'
)

.

.

!
"

&

& #

$


⇒
K
010 3&
1

100.0 000 3& K

0
/ '012(
⇒
------------ ------------ Edition 12.00

OCTAV1A Fuel Formation/Injection 23
Disassembling and assembling air filter
1 - Air mass meter -G70 6 - Filter element

♦ inspecting ⇒ page 23-35.
7 - 10 Nm
2 - Gasket ring
8 - Air filter bottom part
3 - Air filter top part
9 - Air guide
4 - 6 Nm
10 - 6 Nm
5 - Air guide
♦ in air filter top part guide
Edition 01.04 ------------ 23-7.2 ------------

S00.5111.56.20
23 Fuel Formation/Injection OCTAV1A
Removing and installing injection

pump
♦ 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 remov-
ing high pressure lines.
- Cover the openings with a clean cloth.
- Remove plug from the intake manifold pres-

sure sender and the intake temperature
sender.
- Remove air guide pipe between charge air

cooler and intake pipe.
------------ 23-8 ------------ Edition 01.04

S00.5111.56.20
- 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
- Take off cover at inspection opening.
K- 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 refer-
ence 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
K- 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.
Edition 03.98 ------------ ------------

S00.5111.52.20
K- Screw in adjusting device for TDC MP 1-313

as shown in illustration.
- Set adjusting device to 91.4 mm (the left-

hand 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 cen-

tred 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 pro-
duced at the other end of the adjusting
straightedge. Insert a feeler gauge equal to
half the clearance measured, between ad-
justing straightedge and cylinder head. Now,
rotate the camshaft until the adjusting
straightedge touches the feeler gauge. In-
sert a second feeler gauge with the same
thickness at the other end between adjust-
ing 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 al-
tered and can no longer be set with work-
shop tools.
------------ ------------ Edition 03.98

S00.5111.52.20
- 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 con-

nections of the injection pump.
K- Unscrew the securing bolts -1- at the mount-

ing bracket.
Note:
On no account, slacken the central nut -2- of
the injection pump sprocket otherwise the ba-
sic 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 injection pump into the mounting

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

!

!
"

"

#

&

$

!
"

$
%

&

K

(

'

&

$

)

Note:

*
%
+
,
"

-

$

K

/
01
.
K
------------ ------------ Edition 12.00

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 injec-

tion 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 di-

rection of rotation of engine until the crank-
shaft 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:
- Tighten the bolts attaching the injection pump

sprocket to 20 Nm + ¼ turn (90°).
- Remove locking pin 3359.
Edition 03.98 ------------ ------------

S00.5111.52.20
- 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 in-
jection 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.
- Close the return-flow pipe.

- 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 pres-

sure sender and intake manifold tempera-
ture 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.
------------ ------------ Edition 03.98

S00.5111.52.20

!"#$%
t and
commencement injection
Notes:
♦ Commencement of injection must always be
checked and set, if necessary, after replac-
ing 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 injec-
tion is only possible in function 04 Basic
setting of engine as, during this function, the
commencement of injection valve is con-
stantly actuated and the injection timing de-
vice is thus retarded.
t t and

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
- Select function Basic setting, display group

001 ⇒ page 01-21.
Initiate basic setting 0 → K- Check readout in display block 7 (coolant

1 2 3 4 5 6 8 9 10 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.
K Specification: ⇒ Figure - range C

A - Display block 2, commencement of injec-
tion
B - Display block 9, fuel temperature
C - Specified range for commencement of in-
jection
Edition 12.00 ------------ ------------

S00.5111.54.20
3 * +!%)5!
4 ,- 6 9/01"$2
&.
=(':#(8$"; 7 <
(!)48

IJKLM >%FH3!?G@A
8B

5$C4&D97 ?(E
4

$
'" $

K ⇒
Note:
Provided the check reveals that the commence-
ment of injection is within the specified range
-C-, it is not necessary to carry out any new set-
ting. After replacing the injection pump and the
engine control unit, the commencement of in-
jection should be set to the mean value.
⇒
⇒
8
------------ ------------ Edition 12.00

- 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 -2-
for 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 injec-

tion 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 pres-

sure sender and intake manifold tempera-
ture sender.
- Install top engine trim panel.
- Install right headlamp ⇒ Electrical System;

Repair Group 94; Exterior Lights/Bulbs/
Switches.
- Once again check commencement of injec-

tion 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.:
- Replace engine electronics control unit

⇒ page 23-20.
Edition 03.98 ------------ ------------

S00.5111.52.20
Removing and installing and test-

ing 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

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 return-

flow pipe (injector of cyl. 3).
Note:
Always remove all of the injection pipes. Do not
alter the shape.
- Unscrew securing bolt, take off tensioning

clamp and remove injector.
- Shop-make the following auxiliary tool for

injectors which are tight:
------------ ------------ Edition 05.97

S00.5111.51.20
OCTAVIA ##
$ .-
(
!

;
)
- 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 in-

jection 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:
3
,

!
Note:
&

6

77
- 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
!

and activate the function Reading measured
value block ⇒ page 01-28.2.
Reading measured value block 13 → K- Reading measured value block, display group
0.82 mg/H -0.12 mg/H 0.49 mg/H 013, engine in idle ⇒ page 01-47.
Specified value: -1.50 mg/H...+1.50 mg/H

(milligram per stroke)
- If one or several specified values are out-

side the tolerance, interchange the injection
nozzles (except for the nozzle of cylinder 3).
% ,,- ------------ 23-17 ------------

S00.5111.55.20
- 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 rel-

evant 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 pres-
sure and may cause severe injuries.
l Pressure gauge switched on
- Slowly press the pump lever down. When

fuel ejection starts, read off the ejection pres-
sure. If the ejection pressure differs from the
specified pressure, replace the injector.
New injectors 19...20 MPa

Wear limit 17 MPa
Testing for leaks
l Pressure gauge switched on
- Slowly press the pump lever down and main-

tain 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 Fuel Formation/Injection 23
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.) al-
ways 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 con-
necting the measuring cables and comply with the
test conditions.
♦ Test box -V.A.G 1598/22- or -V.A.G 1598/31-
Test 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 1598/22-
K- Connect test box -V.A.G 1598/22- to connec-

tor of wiring loom.
- Perform test as described in the relevant re-

pair sequences.
Edition 01.04 ------------ 23-19 ------------

S00.5111.56.20
23

R5HIV45*6M

LJ3
7T
Y
6)P782+/8N99E(:UW:XKO
0Z<;
1<F=
,

&G'
JRL?H@
>
Fuel Formation/Fuel Injection
Notes:
♦

"5IAPBCED.9#NE$6%F5&K/'7*UGRH8(HO
!SM
-
OCTAVIA

0:)6PE6LI9J2KS1N5Q<
[\]^_`
♦
#
------------ ------------ Edition 12.00

Edition 12.00
S00.5111.54.20
------------

------------
23 Fuel Formation/Injection OCTAV1A
Replacing engine control unit


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

⇒ page 01-2.
038906018.. 1.9 l R4 EDC G00SG 1002 → K The control unit identification appears in the dis-
Coding 00002 WSC 01234 play, e.g.:
- Part no. of control unit part and write in cod-

ing.
- 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 con-

trol 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 immobi-

lizer 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 ä
- Generate readiness code ⇒ page 01-26.
------------ 23-20 ------------ Edition 01.04

S00.5111.56.20
Edition 12.00
S00.5111.54.20
------------

------------
EM O+
T
LFHCN

/5C5J6,-G7
U
M=-!G'3.8
&7
5H/0>3:-K0@+

"K/#0$4
%

'9A,F09J1:1(>.622*I,3?I=@4
'A.,FO/35-B

!
7
:04
6J5Q
C1P+
(
%
8
9>GJ7

.RC:K/,8
;) *
-22I3.-C3/-F5=CJ>010=,,,
3,WVS==AHM9IM;:FX616KHG5<
D C/Vàbc4KE-[T
>=5@de Z\
Y
,C< = VC@ R
.KI.3,0=F/6F->55J]1S4 W 61
IHGVK=3C,24 2
>/PA-05JSFG.KCH=CV1,3>2< I .
F A4
MO05
tem
e
and
Warning!
Have a second person operate V.A.G 1552.
⇒
→ K !
♦
------------ 23-22 ------------ Edition 12.00

OCTAVIA

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 con-

trol 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.
ä
Read measured value block 11 → K Specification in display block 3:

3090 rpm 1866 mbar mbar 62 % 1800...2050 mbar
ä

ä


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 tun-

ing.

------------ ------------
S00.5111.54.20
Testing charge pressure control so-

lenoid valve (N75)
♦ 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

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

⇒ 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 connec-

tor.
Diode test lamp must flash.
Diode test lamp flashes.
- End final control diagnosis.
- Switch ignition off.
- Connect multimeter to valve -2- for resist-

ance measurement.
Models ä 07.00
Specification: 25...45
Models 08.00 ä
Specification: 14...20
Continued for all models
If the specification is not achieved:
------------ ------------ Edition 12.00

S00.5111.54.20

OCTAVIA

- Replace charge pressure control solenoid

valve (N75).
Diode test lamp does not flash:
- End final control diagnosis.
- Connect multimeter for voltage measurement

to contact 1 of connector -1- and to earth.
Specification: approx. battery voltage

- Connect test box to wiring loom to engine

control unit ⇒ page 23-19.

K Test the following cable connections for short

circuit to positive and to negative and also for
open circuit (connector -1-).
"#

$%

&

'
1 2, 28
2 15
- Rectify any open circuit or short circuit in the

wiring.


circuit to positive and to negative and for open
circuit (connector -1-).
"#

$%&

'
1 1, 2
2 62

wiring.
(
)
If no fault is found in the wiring:
- Replace engine control unit (J248) ⇒ page

23-20.

------------ ------------
S00.5111.54.20
------------

------------ Edition 12.00
S00.5111.54.20
OCTAVIA
&'()

$%#"

!"#


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

*+,-
007; engine switched off and cooled down
⇒ page 01-51.
Read measured value block 7 → K- Observe readout in display block 3.

15.4 °C °C 16.7 °C
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- Unplug connector -1- from the intake mani-

fold temperature sender -2-.
- Connect multimeter for resistance measure-

ment to contacts 1 and 2 of the intake mani-
fold temperature sender -2-.

------------ ------------
S00.5111.54.20
#&
*0$ 1
(=)
$
I >?@ABCDEFG '6
234"5 %⇒
7+89:! ;<,
-%%
0
$/ 1235
$46
789:;<H
K=I
H&
,

0
$
>
@
?
1 J
O
-
2

A
B
J 3
C
K4
5 L
6
%
L D
H7 8 E 9
:

F +
;
P
G
- % 0

1
2 M

M
3 C

5
C
$N
N4 D

6
D E

E789:;PH
&
, O
- "
K
50...100
QRSTUV
♦
Test
Test .
1 25
2 1
Test
Test .
1 52
------------ ------------ Edition 12.00

S00.5111.54.20
OCTAVIA
!%&' (
)*

If
⇒
"+!',-#$

S00.5111.54.20
------------ ------------ ./012

*
%
!
+

(
,
-

9
:

#

!
)

.
0
1
2
/

F
D
!

$
;
<
=

3
4

$
%

%

A
B
:

!

)

'

:
;
<

=

&
9
B
D
E
&

5

!
%
)
.
8
,
6
7
>

@

?
!

"
'

&

"

)

!

M@C

:
;
<
=G
H
:
;
<

&
9
K
N
A
>
I
:
&
K
L
=
N
A
B
<J
23 OCTAVIA
9 &

<
B%
K
A
J
O G
H@

!

H
:

9;
&
Testing
,1
38
+
5
2
-
,7 5
sender and altitude sender
P

@

%

Q

R
A
^
_'
!
@
à
H
%
F

%
R
"
&X P

R
<
E

%

%

S

H
)
T

"
(

K

Q

I
J

@
'

!
C

H
H

)

$

;
O

"

)

$
H

R
<
=

"
&
>
G

B

J
&
)

'
testers and aids
U

!
B
R
W %
V
)
@

&
%

H

"
♦
((

)

!

QV
♦ .
" E
G
%

@

H

&)!

H

?
:
;

&
9
@

%



$
!(

.
X
)!
V
♦
" P

H
!G
Y

L
N
J
)
H

T
()
>
B
R
&

V

!

)@
'
B

(
$
!

%
⇒
10 → K
1013 %
[
]
\
Z
⇒
------------ ------------ Edition 12.00

S00.5111.54.20
(
D
11""22 33##44 $$55==E%%66>>&&''B?
!/!/<
< ? --F.::
!! 00 ""##
0077;;))**88++,,99
( $$@@%%B66&&CAA'' (
(
7
7
)
+
,
-
.
*
;
8

)
+
,
-
F
*
;
8
BGK#D

H EIJNOP
0M LE QRSTUV
OCTAVIA

-
⇒
K-

------------ ------------
S00.5111.54.20
------------

------------ Edition 12.00
S00.5111.54.20

$),.23"*%1&+0'(# *!
"/ 0* -0" .##"*$!+
)'$, %2&789<&4%.5+&+6-!(0!#3
(#*$";1:.!*$"#.$
OCTAVIA

ä

=>?@

*

! !
*
! !
♦ white connection points toward charge
pressure control solenoid valve -N75

/

+
♦ for charge pressure control valve

♦ part of turbocharger, cannot be re-
placed separately

! !

! !

------------ ------------
S00.5111.54.20
Testing start of injection con-

trol
Testing injection timing control
range

V.A.G 1551/3
Procedure
- Initiate final control diagnosis and actuate the

start of injection valve ⇒ page 01-18.

Start of injection valve -N108
Actuation of the valve is indicated by a clearly

audible change in the combustion noise (die-
sel combustion noise).
- Initiate the basic setting ⇒ page 01-21.
Basic setting 0 → K Readout in display, e.g.:

42 46 0 20 90 201 64 153 127 83
- Set start of injection, if necessary
⇒ page 23-13.
K- Remove the fuse 34 -arrow-.
- Observe the readout in display zone 2.
Basic setting 0 → K The readout should increase to 255

42 255 0 20 90 201 64 153 127 83
Note:
As a result of the interruption to the voltage, the
start of injection valve is closed. The pump in-
ternal chamber pressure can no longer be low-
ered 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
,5
O7&.C
%-6
$
F

7=L
P

S
R8'
!

U

>
DW
U "
(6
)
/9
4:
!<
N

*
0
1
2
; ?
9
<

=
A
N 3
8
DE

IMB
J

#

G
!
"

#
K

Q

E

F?+ 7@
G
K

A
!
"

#

B
H I
S
T 7

!

J

K

!
V#
T

!

OCTAVIA

If the
⇒ e

K the
If the
If the
If the

------------ ------------
S00.5111.54.20

&

'2

@
*

,
/
.
0
-
5
3
4

"
#
$
%

!

)

(

8
6
7
0
9
1

+

(

'

)

:

"
#
$
%
!

;
8
7
<

=

?
>1
&'

A

"
#
$
B
!

23 OCTAVIA

'

'


C

2

*

,
/
.
0
-
5
3
4

)

(

8
6
7
0
9
+

(

)

:

"
#
$
B
!

;
8
7
<1
⇒
1
Test

>
K
@
G'
'

A

connector at Test .
/
0E
F
8
D
<

5
E
3
9
6

<
)

5
:

H
10
@

K

*I

J
?
+

Test
connector at Test .
14
10 2
M
NO
LPQ
⇒
------------ ------------ Edition 12.00

S00.5111.54.20
OCTAVIA

S00.5111.54.20
------------

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

"
!
%=C
#
<

0

'F
$
2

&

(
)
*

1

3

=

+
7
8
9

6
2

2
0
:
8
;

>

%
,
#
-
.
4
3
5

@
A

/

6

?
2

G

H

B
0

>
F
2

5
3
=
3

D

@

7
4

0
6
E

9

2
3

1

7
8
>

5

C

N
Q
O

6
E

D

K
;
@
K
;
3G

?
K
;
P JJ=
=I6

D

B

1

5

>

Testing temperature sender

M
9

;

6

A
3
=D

K
;K

A
3

=
F
?

9

1;

L

1

6

testers and aids
>

=5

=
♦

.
A
G 4

♦
Test procedure
→ K 1.
S
TU
R
------------ ------------ Edition 12.00
S00.5111.54.20

⇒
⇒

OCTAVIA

Specification:

K

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 specifica-

tion of 1500...2000

♦ A temperature of 80 °C equals a specifica-
tion of 275...375
Replace injection pump page 23-8.

If the specification is achieved:

- Connect test box to wiring loom to engine
control unit page 23-19.


circuit to positive and to negative and also for
open circuit (connector -1-).
"#

'
4 76

7 53

wiring.


circuit to positive and to negative and for open
circuit (connector -1-).
"#

'
4 103
7 111

wiring.

------------ ------------
S00.5111.54.20
23
%)!*+"

#$%&'(!
⇒
OCTAVIA
------------ ,-./0
------------ Edition 12.00
S00.5111.54.20
OCTAVIA

S00.5111.54.20
------------

------------
⇒
Testing exhaust gas

recirculation system
Testing exhaust gas recirculation
Operation of the exhaust gas recirculation sys-
tem 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 ex-
haust gas recirculated, the smaller the signal
supplied by the air mass meter.

V.A.G 1551/3
Procedure for models ä 07.97

001, engine idling page 01-36.
Read measured value block 1 → K Readout in display:

900 rpm 6.5 mg/H 1.480 V 87.3 °C
- 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.
- 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.

900 rpm 272 mg/H 268 mg/H 54 %
- Briefly blip the throttle and then allow the
engine to continue idling.
Read measured value block 3 → K- Check the readout in display block 2 (speci-
900 rpm 272 mg/H 268 mg/H 54 % fied 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
⇒
Fuel Formation / Fuel Injection 23
♦ Fault in fault memory
Read measured value block 3 → K- Check the readout in display block 3 (actual
900 rpm 272 mg/H 268 mg/H 54 % 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 follow-
ing 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:
- Start final control diagnosis and operate the

EGR valve page 01-18.

EGR valve -N18
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.:
- Test mechanical exhaust gas recirculation

valve:
1.9-ltr./66 kW Engine, Mechanical Compo-
nents; Repair Group 26; Exhaust gas
recirculation system
Edition 03.98 ------------ 23-33 ------------

S00.5111.52.20
9 (,Q
C")+ R
S
TUVWX+
/A
?@

(
$

→7

/

'$$3

!
.
0
7

3
<
*
&)9
9
;

D<

!

+

"
#
%
$
'
,
-
)

(
/
"
#
9
8
(

;

&
!
*
"

'

)
+
,
-
(
.
1
2
5
$

"
/

&
+
7
<

,
-
)

!

$

3
5
4
6
:

!
'
#

=
?$'(
&* #
'(&CC 5
*?4 "
+
B> >
4
+

A
(
@

!
5
6<

/
( /

,
-
)
=-"E


!

'
=
ä
7
(

/
#

3

F

$
5
>
/
(

0
+
(
$
B
&
G
H
*
I
J
.
⇒
K i
0
KLMNO
4
Note:
If a constant value of 550 mg/H is shown in dis-
play block 3, test the air mass meter ⇒ page
23-35.
------------ ------------ Edition 12.00

S00.5111.54.20
OCTAVIA

S00.5111.54.20
------------

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

9!

#9( (
4;

"
&?

B
1(

5
$

+)6
2

*
-#<
)
+$
3

'
%
/<7,-"
,
#
.
$

0
3
,
-8+&1=$3/2%:1%1@>)$,3
/
$
)
-9? +(
:C '
4
5
6
7
$
&
*
A
)8
:
-
/
>
3
=
%
Testing electromagnetic
+
*
/
gas recirculation
< ,
$
32 D
:
.
testers and aids
#1 ,*
+
A
$
:
% )
C
>
2
=
Test condition
l 29 and 34
- onnect tester and select

engine electronics control unit ⇒ page 01-2.

- Select control diagnosis and
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 measure-

ment to the -2-.
14...20
the is not
- exhaust gas recirculation solenoid
the is
- onnect multimeter measure-

ment to contact 1 o connector -1- and to
earth.
- ignition on.
the is not
- test box to the loom to the

engine control unit ⇒ page 23-19.
------------ ------------ Edition 12.00

S00.5111.54.20
OCTAVIA

K

"#

'

K

"#

'

!

(
)
"

#
$%⇒

&'

------------ ------------
S00.5111.54.20
------------

------------ Edition 12.00
S00.5111.54.20

!"
OCTAVIA

The signal from the air mass meter is required
by the control unit for calculating the permissi-
ble injected quantity and for controlling the ex-
haust gas recirculation. The smaller the signal
supplied by the air mass meter, the less fuel
may be injected.


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


010, engine idling ⇒ page 01-55.
Warning!
Read measured value block 10 → K- Observe readout in display block 1.

mg/H 1030 mbar 1011 mbar 0.0 %
Specification: 230...370 mg/H
- Test exhaust gas recirculation ⇒ page 23-32.
- Accelerate vehicle in 3rd gear at full throttle

from about 1500 rpm.
- At about 3000 rpm, check readout in display

block 4 and note.

830 mg/H 1030 mbar 1850 mbar % 100 % (accelerator pedal position)

------------ ------------
S00.5111.54.20
23

830 mg/H
830 mg/H
830 mg/H
1030 mbar 1850 mbar

1030 mbar 1850 mbar

1030 mbar 1850 mbar

830 mg/H 1030 mbar 1850 mbar
10
10
10
10
→→
Fuel Formation/ Fuel Injection
100 %
100 %
100 %
100 %
K
K
- Repeat the test and accelerate the vehicle

at full throttle.
Models ä 07.97
Specification in display block 3:

1800...2050 mbar (charge pressure)

>750 mg/H (inducted air mass)
Models 08.97 ä

1700...2080 mbar (charge pressure)

>800 mg/H (inducted air mass)

OCTAVIA
- 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 ä 07.97 = 425 mg/H
Models 08.97 ä = 550 mg/H
------------ 23-36 ------------ Edition 02.99

S00.5111.53.20

O4$2C

S
7C

'3
$0
%%3
'X

?D

!
"
'"#8?9):
1
489:2
;
>!G
=

$Q
#
%M
%G
/VE
/;<
;<
( &

#

?M='/H
D
F1 E

&
(
"
5
1
!
@
=
"F
$$5%L
2
)
J
#%!$'4K/&L !)
2
5 #
A
P $
:
I
&
7 %
2
*
=
J&+ ,

!
B
" "
#-
.

>
@
K
L
2/
6

5
N<
1 I
#
1

6W">&!P Q
/?'%@=$)
GM R
$2"&! (
4
)'% $Q
%$MTL
,
6-U

F2#

OCTAVIA

ä
K-

-
⇒

,

------------ ------------
S00.5111.54.20

H
$
U
C)'7

&

%
(
(

+7
&

'
),3-.
/0
1

38
,3-.
8
2/0
:;
< 9

@1 $

&

4
'
&
>
F9
$*:

= 1

*

&

'
*

;
E
F

5
.
=

D
+

G
$
'
>

/
6
1
!

"

4

' #
$

2
?
A
*
B 0
))?$2341I

D

'J
K
L M N
2'O,PQ:
;ST
1R

t t t
⇒
est .
2
3 4
4 50
5 52
------------ ------------ Edition 12.00

S00.5111.54.20

6
&
#
&
$
$
9
2++,,--..7%'*;A//88"<

(@00:>%11=$
F22"33'$ =
(;(@)DE4 !-5
F,
'"0%>/

3

%"
)
1

?
(
C
B
.

6
2M
:P.;L
$ 7
1@-)N'0?"O523F89 9
D
;
@
A
B 0$ G%*Q;A!%SU G

H
/
0
I
A
@
J
K
1

:
OCTAVIA

K-
RTV
-
⇒
KT

- ⇒

------------ ------------
S00.5111.54.20
------------

------------ Edition 12.00
S00.5111.54.20

034,*

#
0345
%
&5
).
-5
/'

#7)'

1

2

!

'

*
+
,
(
2

6
"

#
"

$

&

"
2
#
$

&

/

(
-.
,< /(;

#=
%

*
& 8
9
:
6

"
12
#
$

&

/
OCTAVIA

*
#>
/5

#

&
$
)&
* 6

"
-2

(

ä

! !

+
,
#6
'!

$
&

"

"

! !
(

♦ models 08.97 ä
! !
♦ models 08.97 ä

! !

! !


♦ part of turbocharger, cannot be re-
placed separately

! !

! !

------------ ------------
S00.5111.54.20

-
.
3

!

"

,

,
"
*
'
/
0
1
2
-
.
/
0
1
(

#
%

$
&

$
'
(
&

#

)
'
*
+
"

#
,

(

5
6
#
#

$

+

9
',
%

"
&
$
'
=
?
@
:
;
<
>
A
B
C

,
#

)
*

$

5
H
J
,
6

+
"
&

'4
#

"

*

"
)
$
(

-
I

"
2
7

,
8

*
2
=
G
D
;
E
F
J
K
7
0
L
J
8
M
N#
1

I
J
K
7

'

OM
P
Q
0
8
P
Q
/7
Testing control unit
2
rameters
=
?
@
@
;
B
R
S
T
A
>
S
;
B
F?
V
@
:
U
A
;
D
W=
?
X
Y
R
>
Testing diesel
rect injection
5
53
0
M
,
N
/
*
'

$

"
(
[
G
@
;
B
:
D
A
<
;
F
D
6
\
'

$

&
#

$
"
*
^
`
b
c
X
d
Y
A
_
a
\

$

&
)Z

2

#

O

]
"
$
0
#
+

$
e
f
g
!

"

)
/
7
M
5
2

)

'
*

"

5
testers and aids
Z
N

)
'
6
h
'
O,

$

2
♦
^
`
b
c
X
d
Y
A
_
ae
f
i
X
♦
5\

#

$

&
)
*!

"

)

'
*
"

5
♦
Z
/

)
'
6
h

'
O,

$

2
T
Test conditions
Test
Test
------------
k
m
l
j
------------ Edition 12.00
S00.5111.54.20
M

". %9;& 2D>'N?E(O0F!
B8!'##/ C-*
"#=RS
$H I@)
G
:AJ
QK:L!345*
6#!+7(<='P$+#!*
$,1,
U
'"T &
>A# !,XQ$:$<!+'QPV@W#=:R'* > A <? !YZ[\
OCTAVIA

-
⇒

ä
Note:
It is not easy to hear the clicking of the relay
and this is therefore best detected by feeling.
-
⇒
- ⇒

------------ ------------
S00.5111.54.20

>

,

+
?

B

&
#
'
!
"
$
!
%
3
'
*
9

)
+
#
(
,
!
*

.
/
1
2
4
5
3
-
0
8
#
!

6
7
%
&F:

*
:

;
!
<

=

@
5
4
A
0

;

;


H

C

D

E

K
F

G

C

E
9

Electrical .
D

contact

B

F

D
E

C

G

E

⇒

ä

B

K

I
J

C

K

Note:


E


⇒
M
NO
LP
⇒
------------ ------------ Edition 12.00

S00.5111.54.20
'
( 6
+
, *3)7/
81

*4 %

0-
#=9>?;.

"0-
<!"25 /

:1420*&-
$
/
' !
#
16

'D')7<=,
' (
6 4 2
)E>&81?/
>*/ ; A
0F4<
?) 4+ 7 > & =B% C 4
/
0

9811 *0*=:
442<:E >+

7 ;

*
10A*@?/ = @
4
OCTAVIA

1GHIJKLM

⇒

K

Note:
*#
+

,
⇒
-

#
⇒
* #

K

------------ ------------
S00.5111.54.20
I
74
; 9
F
3D !<:=5C
"(07.K0LG

6 >N ? E 9
M5
O8 H;

E!J
"-#B $
@7GA 1%2/7&5' 3
3()*+
,
-

XQ
33P4
?
6
6

! !9 "

5#T:KL$ C >
G&BV%
S5N 7
JKTU '
()M7R 5N
)8 *+ ,S
. 9
KW? 5;@7
9
3 53"
Electrical .
contact
YZ[\]^
l
Electrical
contact
------------ ------------ Edition 12.00

S00.5111.54.20
=B!.(>(F"/68
H8IJKL9M%<1+ N:2 %CA,G9; 7?:*$

-0).2!/0@)D
!&"3"$&'+'**,?E44!
O1<55--G6677))22
#-<//##,..
=!>()%+A?P*;&Q@" $)%?'"RS#TUVW*
OCTAVIA

K-

-
⇒
- I
- he
⇒

-
⇒

------------ ------------
S00.5111.54.20
%A
@ $*

+
*
'6<D.& $123C
!>"B=,&/0#+-
%?'4-
F
E56
(7G H"I#)+J,K,!'.8
"%#&()B $?9L0/":;&+-
'(6I B 2 )1,
@ $M
A
N*+'-
$* D<
$("B,/ '
O
+
.>P
20C -
%
%
,
4&B+'.8

0)/:;&B
9 N +
% ?J
62 1,
Test
K
r
Electrical
contact
QRSTUV
⇒
Test .
4
4
5
5
------------ ------------ Edition 12.00

S00.5111.54.20
# E
5
C$%H
(*-)J8*"K
D&2F
"71I'
?V0L
4
P7Q8R=ST@A93!""W4
,<U2O6
/+MN 5

7'89G@0:AB29;
".=/>
-U%6
HX
F
]
2Z[-$'\^b&)*3F 79B_ < 2 ? ⇒
W%,D-(2C"!I*J2+K F
9
B 3
76

=
@
;
":&L a7M"N %̀DcOdPefQgRST,
OCTAVIA

The

♦ T

he he

------------ ------------
S00.5111.54.20
23

!4?
#(;7%0GL$#:HI=:.
0<56&#78@E9A.
+
"
!"
F8.
2B
Test
Ω

⇒

$%:>,0;-<*1%=02!3.

% $
OCTAVIA
&'( 0)
/ *
A#$&J(K%*0C
)9 $:;
>
D
MNOPQR
Test .
1 102
2 110
------------ ------------ Edition 12.00

S00.5111.54.20
OCTAVIA

S00.5111.54.20
------------

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

$

%
%
"

(

"
,
.
/
)
*
+
-
0
1
2

!

"

#

"
"
#
&
'

$

,
6
3
*
4
5

#

#
7
9

"

8
9

A

$

:
;
?
B
C
=
<
8
9
:
;
=
>
<

?
@
B9
&
C
D
;
#6
/
*
1
)
3
0
+
*
5
3
E

%

Testing needle sender

#=

"

"
#
#

F

E

"

J

"

B
H
;
=
$
I
G
%

!

"

K
;

#

%
H

&

G

D

!

#

%
testers and aids

$
:
B
H
&

♦

G
♦
L
N
P
Q
0
M
OR
T
U
V
W
S
♦
#F

A

%

"

⇒

=
D
;
?

#

%

"

K

#$
"

W
,
)
Z
+
0
Y
.
[
3
\
]
;
J

!

%

;
&

#

/
*
+
0
3
-
Z
2

"

L
N
0
M
>

P
Q
R
T
U
V
W
S
O

2 Test
_
à
^
Test .
socket
2
2 55
------------ ------------ Edition 12.00

S00.5111.54.20
OCTAVIA
</
)
#:

-

⇒
"#

$01%,293**;(4"
5

'

+.!6!"-78#$
%&'

(=+,>#"?@-
* 9"!'
&!
.
ABCDEF
-
(
)
- ⇒

------------ ------------
S00.5111.54.20
------------

------------ Edition 12.00
S00.5111.54.20

"
#
T
$
HH]

$
%
2
1

E
D
O
,
*
V

!
&
(
'
3
4
5
<
=
G
F
N
P
#
-
)
W

3
9Y
5
:
N
;O
ZHE
[Y
9^ )
*
+
6
9
7
8

H
;
Q
R
.
%
0
2
U
G
E
M[$2*F
9T Q ,
$
:
@
A
B
I
$
4
K
I 2

-
<
;

1
C
J

S
P
F
⇒6'
A
K
Q

&
.
*
-
$
/
=

>

U
G
4
5
7
B
V
2
:
I0
?

N
4
9
E
8

H
J
3
L
S
K

\@
<
A
;
Q
6M
I
F
9
6N
R
;I
B,Q
P
4_7
4;;N
ZF)3 2
69572à
? F
Z5Gb
K Q
H7c
J: > = N
P
7
2
;QGMA
L
MI6E4deJ9f= 3
G
F
9ghi;LZ>
: 5
QNE8 2 :
7H43EF5Q697I;:
2 H
2H
OCTAVIA

♦

♦
♦

→ K

------------ ------------
S00.5111.54.20

-
71?
(
&

:
*
$W
M
J?
#

!

'.8
@

"
)Q
$A
*
+"8
)
X

B
2
4RST
1: ;2

[/E

!

,
/
&
*
%
3
'U%C6D
5

(
"

#

$
F
H
I
K
G

"
#

0
%
8

9

"

$$

%

1
;
<
=
3
>
'
Q
'$*
$8
R@
$W
1:>ST

;N
V
AX
$N
M L
M

.
3
/

⇒
1

9

U

%
N

2
P

"
9

?
@

A
8
"

$
%
N

8
$

B
D
E
F
H
I
J
K
G
C
V
Y
U

6
Z
(
8

'
B
C

%
⇒D E
F
H
I
J
\
G
L
"
.
M
]

3
2
P
1
'

N
#N
1
K

9

9

$

50...100

U
>

$

U
V?
@

AB
D
E
F
H
I
J
\
G
C
V
Y
U

♦
/ 2
♦

[

'

%8

"

$

%8

K
4 104
2
------------ ------------ Edition 12.00

S00.5111.54.20
OCTAVIA
$()*!

If
⇒
"#$%&'

S00.5111.54.20
------------ ------------ +,-./
⇒
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 op-
erated 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 uninten-
⇒
tional governing of the engine speed.

V.A.G 1551/3
Procedure

006, engine idling page 01-33.

0 km/h 000 000000 0
- Check readout in display block 2.
Read measured value block 6 → K Specification: 0 0 0

0 km/h 000 000000 0
- Slowly depress brake.

0 km/h 011 000000 0 Both readouts should jump from 0 to 1.
♦ Middle readout = brake pedal switch
♦ Right-hand readout = brake light switch
- Slowly release brake pedal into rest position.

0 km/h 000 000000 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:
- Test the switches or the cable connections

to the switches.
Current Flow Diagrams, Electrical Fault
------------ 23-44 ------------ Edition 03.98

S00.5111.52.20
'5
.$06%7#C
&RS$T*E /8,2$D
J 9#(:&)
,E

;!+(<.FPG43&

(K+D

=>/!1-
.#$$,2%#NQ*%C
I"0')

'1"F!0#G(/?)
*AO293.$QBL'1ID
.72H@N,- %/M'&$!+&
V$!!)
$V #,#%%3G3G22LL&&)
,) *$*//11J
$) +
'('TTj̀2OkQcW^C
(J Fc
ZlFQb2IZ\
_ 7
,+]
ì =
'$<%) U
V
W
X
0X
M[
Y!B7- 6
?
<
!

F
4 8
)B

* A
7
&

%
3

$ *
/MbQ&) (
' W
K(C T
!
4
F
+
,(;$='/T0c̀^a_*((à,&Y#F.2IOH2`#G4!,QW$G'Z[
# 2, &
T#!3$%M2- * %
$*.)(
'(d0efgh
OCTAVIA

The
The
The

♦
3B 3C
♦ (
♦ T

→ K 4
900 C
ä
→ K
900
ä

------------ ------------
S00.5111.54.20
:O M %
$=
;?@ > #)*J&+-C !2
3
<& '(
#8./F
=>.!0"
?/ 4!"5
*6+7",#-
9

0 #
9">A/+KB-N('B D&*L,G11EHI6

P@

4
&
G

1 /

. +
C Q B -
#
?
!

A
/
B

R #
* -, S
23 OCTAVIA
, T !


- U "

⇒
VWXYZ
Electrical
ment and
Injection pump
connector
2 4
2 4
ä
5
ä
and cable
connector at
------------ ------------ Edition 12.00

S00.5111.54.20

+

+
,

#

)/

0/
4@
7
1

.0

!
"
2
3
$

5

9
:

%
'
&

6

(
*

2
8

-

$
%
!
#
"
:
9
;
<

>
=
?'
&(
)
*
.

@
1

#

,

2
A!
3
A

7?
$

5
.

%
'
)4
" &
6

B
(

2
8

-

!
$
%
#
"

?
>'
&(
)
B
.
OCTAVIA

9 :

=
If the
:
t the the

,C

⇒

K the
< >
-

"#

'
the
E
FG
DH
IJ

K the
"#

'
the
(
)
If the

------------ ------------
S00.5111.54.20
------------

------------ Edition 12.00
S00.5111.54.20
LJ
1
LQ

!
"
H
#
8KL46GEc= )
?R_

#

%
$
/
2
>

I
"
J
L
6
O
?HN0O
&
+ M'
3
(

?$(

14

)
*
0
1
9
:
5
;
8

D
F
.
-
#

A
7
NL.P#4S'()TA0@NU
PV

<
G

C1 /

@ N2
A

3
=

K

4;

+
#
6
5

6

%
,
-
7
D
E

L
4

0
?
Q
.
B
G
9
:

8
2

@C

O
7
6à:WX

0 8 :
?bYZ[N\]^4LA?K@3
Pb7
7
DC0CNA??
OCTAVIA

The
he

defgh
♦
♦ T
→ K

→ K

→ K

ä

------------ ------------
S00.5111.54.20

*+

8

!
&
$
)

#

$
%
"
&
(
∞
#

%
"
-

.
/
0

1
2
"6

+

,

23 OCTAVIA


7
3
,

9
:
;4
5

K
&

!
)
+

=
)
<

"
0 Ω
0 Ω
6 0
*+ >

+

,

Ω
?
<
@1
&

3"+

A
6 0
3 4
!

Ω
C
DE
BF
⇒
------------ ------------ Edition 12.00

S00.5111.54.20
Test the wiring between test box and connector

of sender for open circuit according to the cur-
rent flow diagram:
6-pin connector at Test box V.A.G 1598/22,

wiring loom, contact socket
1 24
2 11
3 23
4 12
5 8
∞
6 25

wiring.
If no fault is found in the wiring:

23-20.
Models 08.98 ä
- 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 Specification

not depressed 4+3 0.6...1.4 k
depressed
depressed 1+6 0.6...1.4 k
not depressed
- Replace accelerator pedal position sender

(G79).
Edition 12.00 ------------ 23-48.1 ------------

S00.5111.54.20
K- Test voltage supply of accelerator pedal po-

sition sender:
6-pin connector at Specification

wiring loom, contact
2 + earth approx. 5 V
2+3 approx. 5 V
1 + earth approx. 5 V
1+6 approx. 5 V
- Connect test box to the wiring loom to the

Test box V.A.G 1598/22
K Test the wiring between test box and connector

rent flow diagram:
6-pin connector at Test box V.A.G 1598/22,

wiring loom, contact socket
1 8
2 11
3 23
4 24
5 12
6 25

wiring.
------------ 23-48.2 ------------ Edition 12.00

S00.5111.54.20
1
7$
%.&82'9/()*0
- 3+4,!
56
;!<=

"
#
>:
K Test the wiring between test box and connector

rent flow diagram:
.
wiring loom, contact
- open circuit or short circuit in the
no fault is found in the wiring:
- engine control unit ⇒ page
Edition 12.00 ------------ 23-48.3 ------------

S00.5111.54.20
------------ 23-48.4 ------------ Edition 12.00

S00.5111.54.20

# $! #$%
&
'
*"

($)

+
-&'$#*(.',*/('
& ,
additional
and to air
The AC compressor is switched off by the en-

gine control unit in the following situations:
♦ when accelerating from a low speed (recog-

nised by change in angle and accelerator
pedal position sender and from the vehicle
speed signal)
♦ in the emergency programme (emergency
01234
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 t and

V.A.G 1551/3, 3A, 3B or 3C
♦ Hand lamp
Final control diagnosis → K- Initiate final control diagnosis and actuate AC

AC compressor control compressor control ⇒ page 01-18.
AC compressor must stop within 5 seconds

(visual check with hand lamp), and then run for
5 seconds and stop again.
If the AC compressor does not switch off:
Edition 12.00 ------------ ------------

S00.5111.54.20

*

$

$
&
'
(
"
#
%

!

+

-
,

&
'
(
)
4
%

/

3

)

"
.
/

0

8

9
5

-

,

1
2

3
5

6

-

7

*

.
:

+

;

"
#
$
&
'
(
%

!

-

+
,

<

-
,

$&
'
(
<
4
%

/

3

="
.
/

0

8

5
9

1
2

3
5

6

-

7

⇒

>-
:

2+

;

@
A
D

?

B
C
0

@
D

contact
>

E
/
2
2
E
F
0>
D

E
2
C
16

*
-

;

-

;
⇒

-
;

+

G

,

I
L
M
-

7
K
:

-

-
+

H

J

-

contact

-

,

7

K
-

7
M

=
N

;

⇒
------------
PS
QR
O
------------
⇒
Edition 12.00
S00.5111.54.20
→

Read measured value block 2 K Specification in display block 3: X X 1 (AC

900 rpm 0.0 % 111 18.4 °C signal)

Test the wiring for short circuit to positive and to

negative and also for open circuit.
. contact

48 ⇒ Current Flow Diagrams,
Electrical Fault Finding,
Fitting Locations binder

wiring.
Test the wiring for short circuit to positive and to

negative and also for open circuit.
. contact
49 ⇒ Current Flow Diagrams,

Electrical Fault Finding,
Fitting Locations binder

wiring.
Edition 12.00 ------------ ------------

S00.5111.54.20
------------

------------ Edition 12.00
S00.5111.54.20
OCTAVIA
# "


!" 23
∞$&'()*
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 t and

V.A.G 1551/3, 3A, 3B or 3C
condition
l Fuses o.k.

006; engine switched off ⇒ page 01-35.
Read measured value block 6 → K Specification in display block 2: 0 X X

0 km/h 000 000000 0
- Depress clutch.
Read measured value block 6 → K Specification: 1 X X

0 km/h 100 000000 0
- End output (function 06) and switch the igni-

tion off.
- Unplug the connector of the clutch pedal

switch ⇒ page 23-2, Overview of fitting lo-
cations.
K- Connect the multimeter for resistance meas-

urement between the contacts of the switch.
Specification:
Clutch not depressed: max. 10
Clutch depressed:
- Replace clutch pedal switch (F36).
Edition 12.00 ------------ ------------

S00.5111.54.20

*

*

$

"

!

+

&
'
(
)
%
8

:
<
=
;

$
&
'
(
)
#
%

-

,

"
#
!
9

1

.
/

,
0

+

-

2
1

3
2
6
3

4
1
5

7
8
>

A

+

?

"

!

#
$
&
'
(
@
%

-

,

,

+

-

$

&
'
(
@
%
8

: "
#
!
9

1
.
/0
2
13
2
6
3

4
1
5

7
8
⇒
>
+B

0=
F+

?

6
C

4

3
6
D
7
E

3

at
>
-

G
contact
1

K

HI

<
;
J

2
at
contact
2 1
2
MP
NO
LQ
⇒
------------ ------------ Edition 12.00

S00.5111.54.20
Edition 12.00
S00.5111.54.20
------------

------------
.3 ?

G
K

115-#
//4002
.
P46H7;Q@
!O
89"59AMB#
<$
D)/E/&%
(>:)%
0!1;I'NF
(+#
*!? -7,@
6-<P+AA0&B"/BCL=I->JF
$ ;!'NHDE#
!),"&
O
d_% "
+D)+HW."/02 $
()$
V1'X9Y,Z
2 !
![-!\
(] % )
,^_+MàbBc()C!E"AI-+,
%
condition
and
RSTU
♦ .
Warning!
→ K
000 000000 0
------------ ------------ Edition 12.00

S00.5111.54.20

!
"#$%&'

Note:
Ensure that the right front wheel does not ro-
tate.

. contact
! "
#$$

%
&!
&'(

)

$

Note:
Ensure that the right front wheel does not ro-
tate.

. contact
'( "
#$$

***

Edition 12.00 ------------ ------------

S00.5111.54.20
------------

------------ Edition 12.00
S00.5111.54.20

&/ ! "#$%&'(*)+,-.
t t and

V.A.G 1551/3, 3A, 3B or 3C
The engine speed signal is required for the rev

counter and for the air conditioning. If an auto-
matic 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:

001; engine idling ⇒ page 01-38.
- Briefly operate full throttle.

rpm 5.6 mg/H 1.480 V 87.3 °C 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.

- Test cable connection from rev counter to

contact 6 of test box for open circuit
Finding, Fitting Locations binder.
- Test cable connection from rev counter to

contact 27 of test box for open circuit
Finding, Fitting Locations binder.
Edition 12.00 ------------ ------------

S00.5111.54.20
$6 ,
9.
44'$+!6
!'3$!'"9/%%0'!
11% %7
5
-3
8:.*$#;<1& ='>&$)
(1)2 #75
' $5$"

@
O
Y PA 5
?
B
S
+ C
D

-
*
E

2

TF
L

U
G
M
$

QV
W 1 %H
N
I
Z
X
AS
" ! B*C
- D

4E
F
G
J
L
K

R

2
T
<

U
5
.

I

! $
[\]^_" .
' & < '
⇒
01
⇒
.
♦
.
♦ .
♦
.
♦ .
control
and
condition
l
⇒
. 1552
------------ ------------ Edition 12.00

S00.5111.54.20
OCTAVIA
038906012F 1.9l
Coding 00001
038906012F 1.9l
Coding 00001
Select function XX
R4 EDC G000AG 2813 →
WSC 01234
R4 EDC 0000AG 2813 →
Test of vehicle systems

WSC 01234
HELP
T

Readout in display (example):

K If G000AG is displayed, cruise control system
is activated.
K If 000AG is displayed, cruise control system is

deactivated.
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.
t
Activate CCS
Deactivate CCS
End output (function 06).
Conduct a road test.
cruise control
11463
16167
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.
testers and aids

V.A.G 1551/3, 3A, 3B or 3C
♦ Test box V.A.G 1598/31
Test condition
23
l Fuses o.k.

006; engine idling ⇒ page 01-35.
Edition 12.00 ------------ ------------

S00.5111.54.20
C

0
2

1

6
7

4

!
"

#
$

%

2

0
3
5

'
%
&
(
)

*

0

$
.
+
,
(
-

/

0

C

0
2

8

$
%

#
)

!

!
-
(
*

"

G9
%
"
+

$

8
"
>
@
A
B

? :
$
!
"
;
(
<
.
=

+
6 4.
C
D

→ K
0 000000 0
D

>

E

F

@
F
B
?

.

KH

I
J

3

6 → K 3.
0 000000 0
3
000011
001011
000111
000001
000000
010011
100011
LMPQ
NO
.
------------ ------------ Edition 12.00

S00.5111.54.20
?6E9)
7;,-1 E
>*6 +
!"3#0:B.48C/ D@8: 05
92A F'
"$1∞2(3=%#0&!
? 8
6:S!"\ETX# U(:8.05V '21 &

GX$YZ8 .HC([I@J.3 K4WL]EM ^_`NOaPQR'
K
connector
at
contact
Ω
Ω
Ω
/
6
connector at .
⇒
Edition 12.00 ------------ ------------

S00.5111.54.20
>

?"4:H
<
'O
&.
S/

&T
!

%#'
@#A("B(/
-!)$=(.

C=!;$*

%3D,%(&7
!30
6
"9,3B)A7

$ '
&&)I1+JEM5(P8#QR$-*
" #$ (
!2!"36
'

/
0

5
6
7
(

F
G
E
I
J
M
N )
*

"
$
/

3

*
$
"

K
L
2
CT@`
. ?
EYZC[O
%%&'
1&$*
G
&6
!3XC[/
")")(!WRA8#,3=K\ %](7
$LU
&*
I
M
P
J

" ,
#

)
Q
R

K

5

*
$

,

3

#
V

? A
Z

@ "
=
E
B
]
^

_
ä
!
$
. 1552
abcde
and
♦ .
condition
readout not
------------ ------------ Edition 12.00

S00.5111.54.20
OCTAVIA

"#

!$

%
'
(
&

$

⇒
23
Edition 12.00
S00.5111.54.20
------------
*
-.
,
+
)
------------
Servicing intake manifold flap 08.97 ä
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 11 - Vacuum supply
then opens again. This reduces the engine stop ♦ From vacuum pump
jolt.
Testing intake manifold flap changeover ⇒ page

23-57.
------------ 23-56 ------------ Edition 03.98

S00.5111.52.20
OCTAVIA
"#$

t
i
t and

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

♦ Current flow diagram

23
%&'()
condition
- Start engine and run at idling speed for about

5 seconds.
- 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 at-

tached 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 po-

sitioning element.
- Operate hand vacuum pump.
♦ Intake manifold flap must close.
Edition 12.00 ------------ ------------

S00.5111.54.20

*

)
$

!

"

#

%

&
'
(


)

&
,
+
-

♦

*

)

.

/

1
2
+

0

&

t
2
/

4

5

0
,

6
2

2
3
.

'

.

7

⇒

/

&
'
0
(

K
:=
;<
9
.
t t t
------------ ------------ Edition 12.00

S00.5111.54.20

8!!3

67

54

42:..5$$
"))// ##9%%&&''((""))001
" #..3434**++,
1 # '
'
,(
-
(
-
6; 7
?(42'!<E8$=>*+#01
@ABC5D!
FGHIJKL
.
Edition 12.00 ------------ ------------

S00.5111.54.20
------------

------------ Edition 12.00
S00.5111.54.20

/23+($%-5)" '
"6078&,.1' 44(
)*+,!#"#.$& &"1!
./23+)-(%
9:;11&",#&0.$!"' 44$)*+!"##&$
ä0 0
1 recirculation
<=>?@
2
3 o air
Vacuum
Vacuum element
♦ models 08.97 ä
♦ models 08.97 ä
1 Vacuum element

Vacuum unit
o air
control solenoid
Pressure unit
♦ part of turbocharger, cannot be repla-
ced separately
10 recirculation
11 Vacuum
12
13
Edition 12.00 ------------ ------------

S00.5111.54.20
OCTAVIA Glow Plug System 28
Testing glow plug system
Testing operation
♦ Hand-held multimeter (e.g. V.A.G 1526)
♦ Current flow diagram
Test conditions
l Diesel direct injection system control unit

(J248) o.k.
l Strip fuse for glow plugs (S 132) o.k.
Test procedure
K- Unplug connector -1- at the coolant tempera-

ture 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 car-
ried out when the ignition is switched on.
- Unplug the glow plug connectors from the

glow plugs.
- Connect the multimeter for voltage measure-

ment 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.
During the simulated glow plug heating opera-

tion, the glow period warning lamp (K29) should
come on.
Edition 03.98 ------------ 28-1 ------------

S00.5111.52.20
28 Glow Plug System OCTAVIA
If the warning light does not come on:
- Test glow period warning light ⇒ page 28-2.
Testing glow plugs

♦ Diode test lamp (e.g. V.A.G 1527 B)
♦ Hinged wrench for glow plugs (e.g. 3220)
Test condition
Test procedure
- Unplug glow plug connectors from the glow

plugs.
- Connect cable of diode test lamp to battery

positive (+).
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


V.A.G 1551/3, 3A, 3B or 3C
Test condition
l Fuse 29 o.k.
------------ 28-2 ------------ Edition 12.00

S00.5111.54.20
OCTAVIA
Final control diagnosis

Glow period warning light -K29
→
Glow Plug System
-
Initiate final control diagnosis and operate
glow period warning light ⇒ page 01-18.
The warning light must flash.
If the warning light does not flash:
Connect test box to the wiring loom to the

- Use an adapter cable to connect sockets 1

and 41 of the test box.
- Use an adapter cable to connect sockets 1

and 42 of the test box.

28

Warning light must come on.
If the warning light does not come on:

wiring
⇒ Current Flow Diagrams, Fault Finding,
Fitting Locations binder.
If the warning light now comes on, but not during

final control diagnosis:

23-20.
Edition 12.00 ------------ 28-3 ------------

S00.5111.54.20

Workshop Manual Octavia Engine Fuel Injection 1.9tdi

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Workshop Manual Octavia Engine Fuel Injection 1.9tdi

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

Replaces List of Supplements - Edition: 09.03

Supple- Edition Subject Article Number

Contents ⇒ next page.

The Service Manual is intended only for use within the

23 Fuel Formation/Injection Page

Edition 01.04 ------------ I ------------

28 Glow plug system Page

------------ II ------------ Edition 01.04

If faults occur in the monitored sensors or com-

The engine control unit analyses this fault infor-

Faults which occur only temporarily (sporadi-

The stored faults can be read out with the vehi-

After any faults have been rectified, it is then

Technical data of self-diagnosis

The control unit version is displayed when the

Edition 12.00 ------------ 01-5

Functions available when using vehicle sys-

Please refer to the table below for the require-

Engine not Engine

01 Interrogate control unit yes yes

1) Only perform when ignition switched on if

Connecting vehicle system tester

♦ Vehicle system tester V.A.G 1552 with cable

l Battery voltage at least 11.5 V

l Earth connections at gearbox and on left

------------ 01-2 ------------ Edition 12.00

K- Connect vehicle system tester V.A.G 1552

After the vehicle system tester has been con-

- Depending on the desired function, switch

If the readouts which appear in the display do

Test of vehicle systems HELP

Test of vehicle systems HELP

Test of vehicle systems HELP K Readout in display:

Edition 12.00 ------------ ------------

♦ 038906018BQ Part no. of control unit part1)

   

   

------------ 01-4 ------------- %  ,,-

♦ Storage of non-existent faults in fault memory

If the code does not match the corresponding

- Check coding of engine control unit ⇒ page

Test of vehicle systems HELP K Readout in display:

Interrogating and erasing fault

♦ Vehicle system tester V.A.G 1552 with cable

Interrogating fault memory

- Connect vehicle system tester V.A.G 1552

Only if the engine does not start:

- Switch ignition on.

Test of vehicle systems HELP K Readout in display:

X faults recognized! K The number of stored faults or No fault recog-

Test of vehicle systems HELP K Readout in display:

Edition 12.00 ------------ 01-9

If one or several faults are stored:

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

The stored faults are displayed in sequence.

Vehicle system test HELP K Read-out on display:

- Rectify fault by referring to the fault table

- Enter 00 twice for the address word Auto-

Erasing fault memory

For vehicles 08.03 ä

- Connect vehicle system tester -V.A.G 1552-

------------ 01-4 ------------- % ,,-

X faults recognized! K The number of stored faults or No fault recog-

- Enter 00 twice for the address word Auto-

------------ 01-8 ------------- % ,,-

% ,,- ------------ 01-13 -------------

% ,,- ------------ 01-15 -------------