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The Workshop Manual is intended only for use within the KODA Organisation; it is not permitted to pass it on to third parties. 1996 KODA, automobilov a.s.
Service
List of Supplements to reparationshndbog for OCTAVIA
Edition: 12.00
1.9 l/50 kW (SDI) Engine - Fuel Injection and Glow Plug System
Replaces List of Supplements - Edition: 07.99 Subject
Basic Edition of Workshop Manual Supplement to Basic Edition Modification of Fault Codes Modifications for vehicles 08.00
Supplement
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
The Service Manual is intended only for use within the Skoda Organisation; it is not permitted to pass it on to third persons. 2000 KODA AUTO a. s.
Printed in CR S00.5113.53.20
OCTAVIA
01 Self-diagnosis
Contents
Service
01-1 01-1 01-1 01-2 01-5 01-8
Self-diagnosis .............................................................................................................................. - Features of self-diagnosis ........................................................................................................ - Technical data of self-diagnosis ............................................................................................... - Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit .. - Interrogating and erasing fault memory .................................................................................... - Fault table .................................................................................................................................
Page
Measured value blocks ............................................................................................................... - Reading measured value block ................................................................................................ - List of display groups ................................................................................................................ - Specified readouts for general vehicle check ........................................................................... - Specified readouts for injection pump ...................................................................................... - Specified readouts for engine idling ......................................................................................... - Specified readouts for exhaust gas recirculation ..................................................................... - Specified readouts for temperature sensors ............................................................................ - Specified readouts for vehicle power output ............................................................................ - Specified readouts for charge pressure control .......................................................................
Final control diagnosis ............................................................................................................... - Performing final control diagnosis ............................................................................................ - Basic setting ............................................................................................................................. - Coding control unit ...................................................................................................................
01-23 01-23 01-24 01-28 01-31 01-40 01-43 01-43 01-44 01-47
23
Servicing diesel direct injection system ................................................................................... - Safety precautions .................................................................................................................... - Rules for cleanliness ................................................................................................................ - List of fitting locations ............................................................................................................... - Removing and installing air filter and throttle valve positioner ................................................. - Removing and installing intake manifold .................................................................................. - Removing and installing injection pump ................................................................................... - Dynamically testing and setting commencement of injection ................................................... - Testing intake manifold temperature sender ............................................................................ - Testing throttle valve positioner -V60- ...................................................................................... - Servicing injection pump .......................................................................................................... - Servicing fuel filter .................................................................................................................... - Servicing throttle mechanism ................................................................................................... - Setting accelerator pedal position sender ................................................................................ - Removing and installing and testing injectors .......................................................................... - Replacing O-ring at injection timing cover ................................................................................ - Testing cables and components with test box .......................................................................... - Replacing engine electronics control unit ................................................................................. Testing fuel injection control ..................................................................................................... - Testing injection timing control range ....................................................................................... - Testing commencement of injection valve ............................................................................... - Testing fuel temperature sender ...............................................................................................
23-1 23-1 23-1 23-2 23-4 23-5 23-6 23-12 23-15 23-17 5 5 5 5 $ 5 5 5 5 5 5 5
Page
Testing exhaust gas recirculation system ................................................................................ - Testing exhaust gas recirculation ............................................................................................. - Testing electromagnetic exhaust gas recirculation valve -N18- ...............................................
23-19 23-19 5
5 refer to 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System $ refer to 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System (The specifications for the 1.9 l/50 kW - SDI engine differ and are listed in Repair Group 01 Measured value blocks of the SDI engine)
Edition 12.00 S00.5113.53.20 ------------1 ------------
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------------11 ------------
Service
5 $
S00.5113.53.20
5 5 5 5
5 5 5 5 5 5 $ 5
5 5 5 5 5 5
OCTAVIA
Self-Diagnosis
Self-diagnosis
Features of self-diagnosis
The diesel direct injection system control unit is equipped with a fault memory. The fault memory is designed as a permanent memory and as a volatile memory. If faults occur in the monitored sensors or components, these are stored in the fault memory together with an indication of the fault type. The engine control unit analyses this fault information and distinguishes the fault types page 01-8, Fault Table, and stores these faults until the contents of the fault memory are erased. Faults which occur only temporarily (sporadically), are displayed as sporadic by the addition /SP. The cause of a sporadic fault may be, for example, a loose contact or a temporary open circuit in the wiring. If a sporadic fault no longer occurs within 50 engine starts, it is automatically erased from the fault memory. The stored faults can be read out with the vehicle system tester V.A.G 1552 or V.A.G 1551, or also with VAS 5051 page 01-5. After any faults have been rectified, it is then necessary to erase the fault memory page 01-6. Notes: The description which follows relates only to the vehicle system tester V.A.G 1552 using the programme card version 5.0. If see info in literature appears in the display of the vehicle system tester, look for the appropriate text in the fault table on the basis of the fault code. Use of the fault reader V.A.G 1551 (with programme card version 8.0) with integrated printer, or VAS 5051, is similar. Slight variations are possible in the readouts in the display.
01
01
Self-Diagnosis
OCTAVIA
Functions available when using vehicle system tester V.A.G 1552 Please refer to the table below for the requirements necessary to enable you to select the desired functions. Function Condition Engine not running, ignition on 01 Interrogate control unit version yes yes1) yes no Engine idling yes yes
02 Interrogate fault memory 03 Final control diagnosis 04 Basic setting 06 End output 05 Erase fault memory 07 Code control unit
yes yes
yes
yes yes
yes
yes
yes
yes
yes
Only if engine does not start (starter must be operated for at least 6 s).
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.
2 C & ! ! ! `" Y $ A ! S & ! ( ! " % F R $ $ $ X % 0 ! $ $ W # % ! # ! ( ! % ! ! ! % ( ! " " ! ! $" 'I V! $ A%% " !& # % %"" &1 $ $ % ( % !" V"T$ $A" V " P1 V & ! ( ! # A "" 0 $ !& ! 0 0 & ( ! ) " ! 0 $ $! % %" 0 & ! % 0 0 % # % $# $ $ C % % % ! ! # D ' ' A( Q ! ( ! % ! ! " (! %" 0 H& FT% RQ Q &" ! & !( #! ) !! ( ! ! 0 0 $ $ P $ ! A "% !!" $#" !"" "U! % "! " ' ! " '% ""( D I & % " ! ( % 'A $ CIC& C "$ ""# S ! " " "Q ! ! G G!! " E"" D B" H F( @A%" 8 6U 4! 8 7 5 5 9Q! 3
T T T T T Self-Diagnosis K K K If one of the following messages appears in the display, perform fault finding according to diagnostic cable fault finding programme: Operate the vehicle system tester on the basis of the readout in the display. Note: Notes: If Error in data transmission is displayed because of an input error, disconnect cable at vehicle system tester, plug it in again and repeat the steps. est
-----------------------
OCTAVIA
01
01
038906013A 1.9l Coding 00002 R4 EDC
OCTAVIA
K The control unit identification appears in the display (example): 1.9l R4 038906013A Part No. of control unit1) Type of engine (4-cyl. inline engine) Displacement of engine
# % & $ ! "
EDC G or no readout 00 SG AG Injection system (Electronic Diesel Control) Vehicle with or without cruise control system Control unit maps Manual gearbox Automatic gearbox2) 1504 WSC 01234 Coding 00002 Coding version of control unit Workshop code from V.A.G 1552, with which the last coding was performed Data status (software version) of control unit of of Soft a e 1508 1827 Date of 038906013A 038906013P 08.97 08.97 038906013AS 038906012E 038906013AL 1836 1837 08.97 04.99 08.00 3312 05.99 07.00
1) 2)
Notes:
If the control unit version displayed does not match the vehicle, replace control unit. 1.9 l/ 66 kW Engine, Fuel Injection and Glow Plug System; Repair Group 23 Incorrect coding of the engine control unit results in: Poor handling properties (jerky gearshifts, load change jolts, etc.) Increased fuel consumption Increased emission levels
OCTAVIA
Self-Diagnosis 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 01-22. Press key.
01
HELP
K Readout in display: -
HELP
K Readout in display: -
X faults recognized!
HELP
K Readout in display: -
7 9 @ 8 # 0 & 61 " " ( 3 ! 3 4 4 # 5 0 2 ' 2 # & ' " 0& )" 3 $ ' $ & $ # # & $ & " (" (! ( & ! " 1 " % !
For further procedure Repair descriptions.
and
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
Connect vehicle system tester V.A.G 1552 with cable and select engine electronics control unit (address word 01). Engine should be idling for this step. (Connecting vehicle system tester and selecting engine electronics control unit page 01-2).
Enter 02 for the function Interrogate fault memory and confirm the entry with the key Q.
Press key.
01
OCTAVIA
Fault number: 00542 Needle lift sender -G80 Short circuit to earth
The faults stored are displayed one after the other. Test of vehicle systems Select function XX HELP Press the key.
K Readout in display: -
Press the keys 0 and 6 for the function End output and confirm the entry with the key Q. Rectify the faults displayed by referring to the fault table page 01-8.
Note:
When carrying out test and removal and installation work, other control units may also detect faults, such as connectors unplugged. For this reason, you must always interrogate the fault memories of all the control units and erase them after completing the work. Adopt the following procedure for this: -
Press the key 0 twice for the address word Automatic test sequence and confirm the entry with the key Q. V.A.G 1552 sends all the known address words one after the other.
After rectifying faults, the fault memory must once again be interrogated as described below, and then erased. -
Connect vehicle system tester V.A.G 1552 and select the engine electronics control unit with the address word 01. Engine should be idling for this step. (Connecting vehicle system tester and selecting engine electronics control unit page 01-2)
Edition 07.99 S00.5113.52.20
OCTAVIA
Self-Diagnosis
01
HELP
K Readout in display: Press the keys 0 and 2 for the function Interrogate fault memory and confirm the entry with the key Q.
X faults recognized
K The number of stored faults appears in the display. If one or several faults are stored: The faults stored are displayed one after the other.
HELP
K After the stored faults have been displayed, the following readout appears: Press the keys 0 and 5 for the function Erase fault memory and confirm the entry with the key Q.
K Readout in display:
Note: If you have switched off the ignition between Interrogating fault memory and Erasing fault memory, the fault memory is then not erased.
Press the key. Press the keys 0 and 6 for the function End data transfer and confirm the entry with the key Q. Carry out a road test. After this, once again interrogate the fault memory. There must not be any more faults displayed.
01
Notes:
On vehicles 08.98 different fault codes are displayed with the same or a similar text. In the fault table, select the text required on the basis of the fault code. If see info in literature appears in the display of the vehicle system tester, look for the text required in the fault table on the basis of the fault code. The fault table is arranged according to the 5-digit fault code shown on the left. Explanations regarding fault types (e.g. open/short circuit to earth):
------------
@ B C A 0 ' ' 5 80 95! # 4# 64"1 3) 2 6( ' & %( $ 74 3' %7' "4 75 "4' 5 % " ")
Self-Diagnosis
OCTAVIA
If components are shown as faulty: First of all test the wiring and plug connections to these components and also the earth cables of the system on the basis of the current flow diagram. Only if no fault is found in this case, replace the component. This applies in particular if faults are shown as sporadically occurring (SP).
on
old
new -
of
effects
No exhaust gas recirculation, throttle valve fully opened No exhaust gas recirculation, throttle valve fully opened
No signal
16706
Sender rotor bent or loose Distance of speed sensor/ sender rotor too large Metal swarf on G28 or base loose Open circuit in screening -G28 faulty -G28 faulty Open circuit in wiring or short circuit Open circuit in screening
Irregular engine running, misfiring Poor starting Increased idling speed Glow warning lamp flashes Reduced output No indication of rev counter Engine does not start
- Test engine speed sender 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
------------
OCTAVIA
Self-Diagnosis
01
Possible effects
Rectifying fault
17663
Open/short circuit to positive 00527 Intake manifold temperature sender -G72 Short circuit to earth Open/short circuit to positive 00532 Supply voltage Implausible signal or Voltage supply tml. 15 Voltage too low
17664
17568
-G62 faulty Open circuit in wiring or cable has short circuit to positive
Black exhaust when starting Engine preheating not operating Preglowing always for about 20 seconds
- Test coolant temperature sender 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
17569 18008
-G72 faulty Cable has short circuit to earth -G72 faulty Open circuit in wiring or short circuit to positive
- Erase fault memory and continue checking vehicle Engine does not start Engine stops - Test voltage supply for engine control unit 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Test voltage supply terminal 15 Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder - Replace control unit 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Test voltage supply for engine control unit 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Open circuit in wiring or short circuit Voltage not present when ignition on (terminal 15)
------------
------------
Diesel direct injection system control unit -J248 faulty Voltage supply relay terminal 30 (J322) faulty
H V A D e G R S 6 g ` A Q @ Q S G Q G T G Q R X t v 5 Q d 8 b V H G Q G G G G Q P X X 6 G e s Q S G Q G T @ W G T X s V v A GR Q@ G G G G Q G @ W G T PH X@ X V G Q G X v 5 Q Q @ @ G T I X h Q5V S5V GB5B5B@ TV IUBP v 5G Q5 @D Qh X6 5V Q v D e X Vd VICfS E 5 Ad Dd eY e e GG GS G G @ BG HXb VR AR DBR ee G5 RIRBU SS 66 gur Aq BI8 `U@q AQS QsV @Vg QDF SQS GPA QTfffX GX@ T5A GYBP QB5AIIIIIIBr RBwR XQW IH taGCX 5@R QIA PRIIBB3 R P GPG RP@BP QGP I9VS QY dQV B8@ 8AIT bCXF BB9CR@ VCtIW HX HUA VbdP 5V5 GQ@a QiRd GTCfUTQ GiA GQIB9P@ G9GD QGCCW PQCQ GH S XAG XRG 5aCg 6I99999T hH 6 BV q (II r tIII9PRI Gd QIS G QQX5 SIRDC9B GYY QCH SBGG TYG CQY I@CIP7 9PG IG 5VT E QP PX Q X9P59X BA Q P @ q q 6 8 HR9T VX AyPG DAG SGV eiQPICA9B99CCiIU GA@ RVCh 6CSUA gIG@ ICQIR B`IW BH `H iSX AQX Q@S @aC@G QSG SC@g GC7P7 QGPG GXPV TCQCA GfXQ QB@V RIVP` XsT ITS BiQ IC5VUG t@G 5QGP iPDPPG Q7 Qe PQ7 VG BRG GPQ QS S@ @@ QG duBQ 8@V bWA aCIsD VX VTD E GYS' QYIIGBI GxID G @ X9BPBGQ5B' F sID 5UAIS AAW GhITC9P9BC9PB GQ GUA TD B`IQ2 XA 6 8 7 q ' ' 'I p P' Df %"QG #T@ UGBFPPIICbPI4 !G S a 9 ) C ! !C &QC#99 G@IaICPC V$!C0 #PQIPCCCUb PB5CU9YW2 Q53 f fICR@B $XG5IC "R9@CI5( $T cBI999" $CSCQI $CBBB9 q 11
sender old Open/short circuit to positive Implausible signal Short circuit to earth Open/short circuit to positive Short circuit to earth lift sender on Open circuit in short circuit Open circuit in or short circuit to positive pump earth loose line or to has short circuit to rotor pump open circuit in open circuit in valve run engine bent or air of
01
Self-Diagnosis
or
Irregular engine
Several stops
ment i be
Possible
at high
at rpm
stops
output
output
light
control
Inspect
spect
est
est
est
temperature
OCTAVIA
pump
OCTAVIA
# 5 9 9 ' ' ' # # # 3 1 # & & ) ( ' ' 7 $ $ $$# %" &! "!" $!!"# # !! # # 8 0" 4 "6"" " 2
Self-Diagnosis
01
on
old
of
Hard gearshifts
of
Control difference
Poor performance at high revs Engine difficult to start Poor performance at high revs
Engine was stalled (within the last 50 starts) Fuel feed (was) interrupted: tank run empty, feed line or filter blocked, system drawing air Open circuit in wiring to commencement of injection valve -N108
- Test injection timing range control 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Erase fault memory, continue checking vehicle - Inspect fuel system
Engine clatters when idling as commencement of injection constantly advanced Several faults may be stored
- Test commencement of injection valve 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Test fuse
No constant commencement of injection possible at Basic setting (display block 2 varies by more than 10 readouts) Irregular engine running, poor performance
1)
01
------------
@ C A A 0 # ! 8B ) 9 7 ( ' ' % 6 ! & 5 4 ( ( ' ' ' 4 & 2 3 0 9 ' 4 ( ( ' ' # 41" 9 3 # 1 4 4 ( ' ' ! % # $) ! !") ! &"" ## $ ( ) $$ $ 7 "1"""
Self-Diagnosis
OCTAVIA
on
old
new
of
Possible
speed signal
Implausible signal or
Open circuit in wiring between speedometer sender -G22 and dash panel insert -G22 faulty Speedometer -G21 faulty Open circuit in wiring between dash panel insert and engine control unit
- Test road speed signal 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Test speedometer sender Electrical System; Repair Group 90
period warning
Glow period warning light not operating Glow period warning light comes on and remains on
- Test glow period warning light 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
nal 30
Implausible signal
Diesel direct injection system relay -J322 sticking Diesel direct injection system relay -J322 faulty
- Test voltage supply for diesel direct injection system 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
CCS
1)
- Test cruise control system 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
1)
------------
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sition sition 00777 ing old Implausible signal Implausible signal Implausible signal in
1)
OCTAVIA
on
new
pump pump in
in
in
in
in
of
Self-Diagnosis
plug
------------
pump
------------
01
01
------------
P F E & E % ( C B A (# 9 8 ' ' @ 0 1 ' ' ' # 1 5 ! 8 ' # 7 4 $ 3 % ! 0 ) ' ' ' & $ (IH$ 1 '' 6 5! '1% IH# H& '12 $ 3 " % H H H( # GD "$ I 1G 1"# # 1 #
Self-Diagnosis
OCTAVIA
on
old
new
of fault
fault
Engine
unit in-
0111
nator
Implausible signal
Open circuit in wiring or short circuit Alternator faulty Voltage regulator faulty
01
- Test alternator Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
01193
- Test signals from/to air conditioning 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 23
heating
Open/short to earth
- Test cable connections Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder - Test low heating capacity relay page 01-17, Final control diagnosis
Short to positive
------------
OCTAVIA
01
old
new
Possible effects
fault
-J360
Open/short to earth
- Test cable connections Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder - Test high heating capacity relay page 01-17, Final control diagnosis
Short to positive
01237
Fuel
valve
Open/short to earth
- Test -N109 page 01-17, Final control diagnosis - Test cable connections Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
01265
17810
Short to positive
Open/short to earth
Short to earth
- Test EGR valve 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 23
------------
------------
01
------------
D B 9 9 % 8 A @ 1 2 7 7 7 % % 8 6 C B 5 5 B B & 5 B B 5 1 4 3 2 0 % $ B 5 ' #) & " # 0& R0 8# % ( %7 ' 8 R0 0 8'%& B 5 &'& &Q E& R Q& P 0G) R0 P R P ! I ' !G' ! & H F "& E 2 (
Self-Diagnosis
OCTAVIA
on
old
of
Short to positive
Short circuit to positive Open circuit in wiring Relay faulty Short circuit to earth
Open/short to earth
- Test glow plug relay -J52 page 01-17, Final control diagnosis
Poor drivability Engine stops Preglow indicator light flashes Jerking, poor output Black exhaust Irregular idling
- Test quantity adjuster 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 23 - Replace injection pump
of in-
Short to positive
Engine clatters when idling as commencement of injection constantly advanced Several faults may be stored
- Test commencement of injection valve 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 23 - Test fuse Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Test commencement of injection valve 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 23
------------
1 8 7 q s 3 3 1 i P 4 8 S 9 0 6 3 3 ( b 1 b 7 T 4 T 7 T q y 3 3 T S T 4 r r x e u t ( 3 3 b 4 8 9 4 P T 4 2 5 y R y x ( 3 b S 9 4 2 5 5 R x 3 3 1 8 7 4 8 T T 9 0 0 q e v 3 ( ( c P 7 8 7 4 T 4 5 3I T)T S T r r x e u t 3 3 ( P 4) 7 9 T 4 7 7 9 0 P 2I 2 5 1 8 7 q s 3 3 1 i P 4 8 S 9 0 6 3 3 ( by 1 7Qc T 4 T 7 T q2 y 2 3 I TS Sc T )9 r r x e u t )Q 1 T 3 (3 3 3 3 ( c 7y T4 72 T SQ)7 T 4 8 0)3 2) Q9 1 8 7 q s 3R 3 3 3 1 i @ PT 42b 89 P S 9 0))8 T 7 4 2 I 6 y 3 3 ( b3 1 73 T0 4T TS 75 T 7 22 q)5 y2 @1 33 ( 3 w 1T P0(Q T77 S2302 T07 83 T4 73 95 3 T)0 39 xc2) r3 rT xT e( u2)y t4 I0T )13 3) c3 c 1 8 8 T 5 qb sT rS w 3Q72) c23 bT P42 4)x T4 SS 43 828 Qb )3)Q RR e32 5 (( 3R 31 3 6 1Sx iT0 b( 17 8902Q0))B 7Q04X STh24 P0)S 4)3W 8902)2) 702)9 95Q 0y 4@ 95 89 g2V 23)a) 8(U yQ(E RT " x5 Q QT 3Q3P 334 3xR 34 v 3S 39 c0( 14)QcT 1Q72)9 @43 PQ4`Q 493A 4Q128 9T)B 41 0)7 8Y 9( 4i y4X Q0i v#Q)I y41 30 3( 37 3 17 i7 @ @ TT 8Qi 7)2 4 7 y1 5 3T ( ( 12 1 T2T 7T 41 4 S 9 4 0)QS 0 29 2 3T 3 ( b7 11 1 @ 70 1 T T 9Q S T 7 8 25 54 6 5 3Q3 30 c1 3 3 ( 1s i1 @Q( @ 1 T4 88 70h 42 70 4 gQT2Q e72 2022 s0Q7 y24 5Q 5 6 Q0 5 377 3Q02( c5 3( ()))2 ()r 14 S32(Q# 4yQt0)9 842Q4 TcThQ( 7(0Q 7T))h20 80I0 9Q24 0902)2 T2g 7)h7 4Q)T 41 S2 93 49 0)4 215 2 d2@20Q)9 r1C )QQSh 3 d e 32Q3S 35uQ 3)hT 22 3 cS)1 @bQH @S22)B b7)2 1Qh1 1Q)2( 1 4)Ic4 79! 0c T( 70)24 (0 T( Tc 9p SG T 0) 29R 2QQ)75 2i2 36 591 502h # ' & $ % Y0 D Dif iQ9Qe2 D2c ( 7 WIcE) 7)2 7T `iQ)0)Q (03 E`3 `)cg2 )Q)2D iQ8 )D P EI22))4 EQ) )) E" E2 "0 yF c022a 77 d)090 Q92)" h! g2D @9E 01 )q" 3 Qi h0 g@ ( 8 A e) D &)I &))2) FQ) f) $ H" d %
old Open/short to on to
OCTAVIA
Open to
Open
to
to
or short or to
of
Self-Diagnosis
on
not
est
est
est
-----------------------
------------
01
01
------------
' ( # % $ $ " ! ! % A@% $ B 8 $$7 @% % 1 & 91 ) @$ 9@ % @% $ 5 5 3 2 0 6 ) 4
Self-Diagnosis
OCTAVIA
on
old
of
Engine
in-
Attempt at manipulation Attempt at starting with non-authorised key Engine control unit not adapted to immobiliser
- Adapt engine control unit to electronic immobiliser Electrical System; Repair Group 96 - Test electronic immobiliser: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder - Code engine control unit page 01-22
Poor drivability
- Test databus 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 23 - Test airbag control unit Body Fitting Work; Repair Group 01
-----------------------
D C b c p e h V ! H D " " P P A g X i P CC H C " " # g A b W T h f q xR " D P " u d d s t w v G f ! H H " C H # I W C P H C W X q q aa H C$x H #D " P H D f p P C C # " W D C b s pC h a" V ! " " H " # # A a " " ! " b d" dV c" W Y f aH E i ! " !C H "W D "C C " " " " P P H B $ hI P' H" D g R V ! "" "# C H! P$ C H "$C D C A R t# g' A QBa p0 b C$"$R ya ##" H`R "# PY$$ D ' C P ' f br"C$G t# Q$HH f" A C"Q C# CaH #Q "W CD G3 H !0 C C H W #C # CH AE$A$ R$$A $B D0 C b d2 cB pV e3 VH V !aH' Hf DC9 "V "CE PA a" " C A# `C X i## C$GI "C H"& H' "D$' " H D C4 C#D ") #9 B bW3 WC $ad TW fC hc q x") V' "D0 "#7 P$C# Ca1 H2 " ! " u#6 d$4 d% ta wH$ v" GW3 $`F sQ$% WC e3 fH' aC$ VC 8 " H % HT HY $" "U "U H#@ H1 5 C "( W I#G $H " UC $2 IrBU3 WC3 S # 1$ )$ C$( 0 3 2 3 ) 3C$$ "2 2$$# "& V" 2X $# 0 '$ $3 $ `$R yE# $' &A$ ("3( $ $E$$ )E#$ (E $P (" (" )#G ) ) ' 4) &
old from No message from on . for for
OCTAVIA
or
or
of
Self-Diagnosis
No
No
pair
oil
air
01
b ) a $ y x W ) 8 S 3 a 6 6 ` R ' w " b Q b 5 ) 5 $ % 3 % $ 6 % 6 # ` 4 U Y d tT 6Y % ` % p r c h h f i s q ) % $ % $ 6 3 a # 6 # ' & w 8 S 6 6 R 3 " ! i b ) $ % # 3 6 ` % % % ' & w i ) % $ % $ # 6 R ' S & " ! c b ) a $ y x W ) 8 S 3 a 6 6 ` R ' w " b6 Q 5(X ) $(& %(6 3 % $ 6 % 6 # 44 YR d T tW 6% %(0v `& %000' p r c h h f i s' q 8 ) S % $ # 3 3 R 6 R " X c 4 8 S0 6 6 R 3 " ! i b ) $0vg %& #4 3R 60V ` % % % ' &' w i0v3 )& &B %&& A $U& %$ $V ( # 6 R '$ S &($ &g "% ! c& b03 )& a $' ' y3 x3 W($ )Q 8R S%2 6&Q `Q RR 33&) a4&& 6% '0vT% w! "8 b6P Q39 50#4@ ))0 $v6H %(U 3&R %#8 6R((& %TR7(T $$ 6% #R0(0 &&% 4&R (a$ 0V% T('80 Y&9(I d' t3(3 ) $( 'I 6%) %$% `3) %0060071 $ &4 pe$%D r%0E c`'C h($ h6 i600 s8) q# " ! 0& ( f66 0#46 V3 )V%'(1 806 S&0 30$'(0 3') Rg$ 6%C R3&( %3&( $' 3%# #)6 R6 % & &&% &3 &&& Xu0((((!& c6$ 4&&03 4% U 0)1 (B 0# " !F G &e0B e FV%3 (((! % FQ ( 0&' ) B# (( E3 H C T((" C$5 u9I % 0 & F3 �&' V%$ " ( Eu9# E$ E' DH E6C D#1& D D4 D B &0 & 77 0(& ( '
old or No message from ----------------------on of
------------
01
Self-Diagnosis
No
No
OCTAVIA
OCTAVIA
Self-Diagnosis
) $ 4 C $ @ 5 # )0 ( $ $ % 2 9 9 % ' $ % 4 $ 4 ' % 5' 5 5 B 0 A 2 2 4 2 4 @ 5 7$ 1' 10 99 $'6 4& %' $&0 'C 4D0 2& %6 $ ) ( $ $ % &'& &3 & # 8@ 56&0 5' 03&0 0$ 0 ! "
Final diagnosis
01 final diagnosis
With final control diagnosis the following components are actuated in the order stated: 1. Commencement of injection valve (N108) 2. Exhaust gas recirculation valve (N18) 3. AC compressor control 4. Throttle valve positioner (V60)1) 5. Fuel shut-off valve (N109) 6. Glow plug relay (J52) 7. Glow period warning light (K29) 8. Low heating capacity relay (J359)2)
1)
2)
Models 09.98 Intake manifold flap motor (V157) Only models with optional equipment.
Note:
To repeat final control diagnosis without switching on the engine in-between, switch ignition off for about 10seconds.
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C est
Connect vehicle system tester V.A.G 1552 and select engine electronics control unit (address word 01). Engine must be idling for this step. (Connecting vehicle system tester and selecting engine electronics control unit page 01-2)
------------
------------
01
------------
Self-Diagnosis
OCTAVIA
HELP
K Readout in display: -
Press the keys 0 and 3 for the function Final control diagnosis.
K Readout in display: -
K Readout in display:
When the valve is actuated, a clearly audible change in the combustion noise can be heard (clattering noise).
- Test injection timing control range 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System Press the key.
K Readout in display:
Note:
The clicking of the valve cannot be heard because of the engine noise and should therefore be sensed by touching.
If the valve does not click:
- Test EGR valve 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System Press the key.
K Readout in display:
What is tested is the AC compressor cutoff. The test step is also displayed on vehicles without air conditioning.
The AC compressor should stop within 5 seconds (visual inspection with electric torch), and then should start and stop again approximately every 5 seconds.
- Test AC compressor cut-off 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
------------
OCTAVIA
Self-Diagnosis
01
K Readout in display:
K Readout in display:
K Readout in display:
Press the key. Activation of the positioner results in alternating changes to the combustion noise (the positioner switches over the throttle valve). Activation of the positioner cannot be heard: Carry out diagnosis of the positioner with the engine off and the ignition switched on. Activation of the positioner cannot be heard: Test throttle valve positioner Press the key. page 23-10. The engine should stop. If the engine does not stop: Switch off the ignition. Unscrew fuel cut-off valve and clean any swarf and dirt. Repeat final control diagnosis; if the engine again does not stop, replace fuel cut-off valve. Continue final control diagnosis with engine off and ignition switched on. Press the key. The relay should click. The switching on and off of the relay can also be observed by the interior light becoming brighter and then dimmer, caused by high power consumption of the glow plugs. If the relay does not click: Test glow plugs relay: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder Press the key.
-----------------------
01
------------
OCTAVIA
K Readout in display:
Test glow period warning light 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 28 Press key.
K Readout in display:
Test low heating capacity relay: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
Press key.
K Readout in display:
Test high heating capacity relay: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
Press key.
HELP
K Readout in display: -
setting
est
l Electrical components switched off (radiator fan must not run during the test) l Air conditioning switched off
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
------------
OCTAVIA
Self-Diagnosis Procedure Connect vehicle system tester V.A.G 1552 and select the engine electronics control unit with the address word 01. The engine should be idling for this step. (Connecting vehicle system tester and selecting engine electronics control unit page 01-2)
01
HELP
HELP
0 6 7 8 9
Display group 000, engine idling (engine warm, coolant temperature not less than +85 C)
This display group is used for the dynamic test of the commencement of injection. The commencement of injection valve (N108) is constantly actuated; as a result the injection timing control is retarded.
System in basic setting 42 63 0 24 19 201 64 0 K Readout in display
Fuel temperature: approx. 40 C (is not achieved at a low outside temperature; no specification) Ignore
Commencement of injection depends on fuel temperature, specifications page 23-6, Dynamic test and setting of commencement of injection Idling speed: 41...44
K Readout in display: Press the keys 0 and 4 for the function Basic setting and confirm the entry with the key Q. K Readout in display: Press the key 0 three times for display group 000 and confirm the entry with the key Q. 10 K Readout in display: (1...10 = display zones)
Ignore -----------------------
' " e " ' & ' " ' & ' e % ' & ' 4 4 g r % p " # & ) $ $ f 67 x ' ' & ' & " ' $ % % ) 4 & $ & b U % hv 4' " " $ 4 & & " $ e " 4 ' " (4 % c Uh 5% %' 5 ) $ & 4 " " (g ' b# UY & c % U 5 h4 % f 0V $4 "X "r $ & " $ e " 4 ' " (" ( ( %& 5 S F G @ F @ E( Q Q g B" F G @ Q 7' )6 $ #$ ' & " ' $ # w(7(( v(($ % g$ 0ci 0 6& ( $4 " $ )y' &) $f6 43 0 '( ' " $ $ 2 2 i$ V r 5g$ p(! "3 #' '$ 4& & "# $ %( q!($!( )6g $(X% #Y& 'r $g #7 ' & ' " wg h vW te '$ 4%e &23((g '#' & $d &c da '(p &W '2 42 q 2 & $ ' (@ s cag %g u( r g pc 4Y &g $W "g7 #fd! '! !W a %!U %g $( eg "$ ' 4 & ' & ' & $ $ $ ' e 2 ( 0 67 ) $ $g % '! " g $ $ $ $ # $ e ' 2 $ & (( %f c !' $ & ' ! ) $2 $ & 4 ' & ' e $ & (g % $ 5( i W g % 6' "gY 'gg 4!(!& & '" &$ 'g &e " 4 ' $" $ $ ' e ' $ 2 $ $ (( %P2DI f&S % TEg 7D 7 ) $D5! $IQ $Q g $ @ #P $ $ 2 ' X0F XeQ V U Y' W'F cB @ SD @ FF 9G @G A@ Q T@ & 2 X X VE a U W W c(S bA UD a a a 2PB T T $(F "'P !" E )G $ $ $ $ # X I XB VgP 5 rQ UF Y( F W !$ S(g4 R23! @((Y2 @(26' GE(! P7 Cg C) G2 I2g @ G F @ F I( G I E Q"5 Q2 Qa 8 B2 2 &( &hr "6$ 'f' $ &c 'W'! &g4 "!(& $' #q & 2Y$ $& ' 2 (( ' $ $ " 22 (% !' % 0 6'% $ $ $'$ 'A0 $((17D $ "7(E '(!`3 Bh6 4y &2 '2 &!2 2d !3 & 2(1 ((q( 5!((2( ( I7 !!( )@ "$$ x &4 '((33 $!73(6 &237 $2 "(( #I H 6 (C ( 9$ %) %(( h!( ((3! 2!$(( 1 B$ & !!!!! !(' 7!f 74 ' # 1(($ Di
of of code
------------
------------
01
fitted
Self-Diagnosis
Note:
The code entered is activated when the ignition is switched on again for the next time.
est
the
the
the the
d the
code the
off
to code the c
the
fitted
f t the
the
OCTAVIA
OCTAVIA
Self-Diagnosis
01
HELP
K Readout in display: Press the keys 0 and 8 for the function Read measured value block and confirm the entry with the key Q.
HELP
K Readout in display: Enter the desired display group number and confirm the entry with the key Q.
Note: The display group number 000 is an example in order to present the sequence.
Read measured value block 1 2 3 4 5 6 7 8 0 9 10 K Readout in display, e.g.: Test of vehicle systems Select function XX HELP Press the key.
K Readout in display: -
Press keys 0 and 6 for the function End output and confirm the entry with the key Q.
------------
------------
F G P I F B 9 E C E 9 A 8 S @ 7 1 ( 0 % 3 # ' F 8 A P ( !%& !4 !B% !A 5)@ 2$7 H 9D$ Q RD "R 6
01
Self-Diagnosis Note:
OCTAVIA
higher lower
skipping
Press key C
Press key C
of
in
Designation
000
1 = Engine speed
001
10 = Ignore
Injected quantity
2 = Injected quantity
002
Idling speed
4 = Coolant temperature
------------
------------
X # ' 4 % G 3 7 7 C i X 4 ' 4 G 3 7 C i X ) # 8 3 4 3 # ) G h D X ) ) G ) % g X 8 G ) 3 7 X 8 8 8 4 3 ) 3 0 4 ) ) 4 ) 3 7 X $ f ) 4 0 # 8 # # % 3 % ) 3 # % () ( &0 & D c" C D X ) ) G ) 4 % 94 R&# R) $ 8U 8 8 )$ #D 4# 3@4 )A4 43 3X 0&V 4U )V ) 4 ) 0 3 3 4 3 # # 3 0 Y$ d7 54 U) ` 2e 1) 1' c $@@0 $&( R6 8 )2&&&8 8 #6 8 #1( #6 46 310 0# )) 4 3 0 4 ) ) 4 0 3 7 cX b $2263 R(Q X4 8 84 8v )T5 85 #pS )@&# 4&Q 3&1&" %@&3 )6 411$ 3&3 4W )1) )5 4t )% 0# 30 &&&$ &3 &&w 73 c8 V3 1(% AS X) )) )4 GG )3 46 '4 4B %E D12@4 U4 Q 5 9#&# RDD R#aU $3U $60 $&V ))D #(0 4)# 30D ##) )8 0b(&A #cS 'p1) 0(1@11T( %2bAA&W #B5 )&8 %&&10% 332 4() !&) 3T( ## (1X 3$ #V 3v 4) (v &$ &W &4v &(T( Y032q d)) U0b&% "E5 `U 2#@ 1)V 2&8 6D @&(3 b$ @4 $Ruuu X 3#yx # )s 3# ( &$ Y)yr D) $ 3 # ) $11R XC $ 3R #1D )D 3# (% # ' % # &a% Y) D) V) 6 W V U " XC $! )@211F )$& G )217 41DA 'D 4# %R 320 )2 0) # ) 8 ) # ) % DD91& U4 S0 T( Q 11 1 2%1 9& 0 0 21 9& ( &2 & P( H( I& I91& 2& 2@
003 in 3
OCTAVIA
Self-Diagnosis
Designation
------------
------------
01
01
1)
------------
" ! !
Self-Diagnosis
in Designation 007 Read measured value block 7 1 2 3 4 1 = Fuel temperature 2 = No readout Temperatures 3 = Intake manifold temperature 4 = Coolant temperature 1 = Engine speed 008 Read measured value block 8 1 2 3 4 009 Read measured value block 9 1 2 3 4 1 = Engine speed 2 = Injected quantity (CCS active)1) 010 Read measured value block 10 1 2 3 4 1 = No readout Air quantities 2 = Atmospheric pressure (ambient air pressure) 3 = No readout 011 Read measured value block 11 1 2 3 4 4 = Accelerator pedal position 1 = Engine speed 2 = No readout 3 = No readout Charge pressure control
OCTAVIA
2 = Injected quantity request (driver request through accelerator) 3 = Injected quantity limit through engine speed (torque limit) 4 = Injected quantity limit based on inducted air mass (avoiding smoky exhaust)
------------
OCTAVIA
Auxiliary heater
" ! !
Self-Diagnosis
01
in
Designation
012
1 = Ignore readout
013
1 = Injected quantity variation of cylinder 4 to cylinder 3 2 = Injected quantity variation of cylinder 2 to cylinder 3 3 = Injected quantity variation of cylinder 1 to cylinder 3 4 = No readout No readout
014
1 = Engine speed
016
4 = Injected quantity request (driver request through accelerator) 2 = Auxiliary heater switched off
017
Read measured value block 17 Read measured value block 18 1 1 Read measured value block 19 2 3 4 2 3 4
Ignore
019
2 = Upper stop value (voltage from modulating piston movement sender) 3 = No readout 4 = No readout
------------
------------
01
------------
B ' B)S) @33( B87 02U 53 9D5 (6 A1 04 96 @S 96 42 4R 9 9 0 F@' D4 I0% 63(Q E04 GCV) HD7S PD@ & 3 9& B 9 9 B)6 @339 B8 02 5S 9D74 (5 A1 06 9T @6 9S 42 4' F@ D0 I0% 63 E04 GCR HD( PD@ "U 4 !&' ( 3 3 Q 7) # $S)& # !
Self-Diagnosis
OCTAVIA
engine idling
not less
201
70
K Readout in display
Injected quantity: 15...45 o.k. If not within tolerance page 01-31, Display group 001
Commencement of injection: 0...88 o.k. If not within tolerance page 01-33, Display group 004 page 01-40, Display group 002
engine idling
not less
201
70
K Readout in display
Injected quantity: 15...45 o.k. If not within tolerance page 01-32, Display group 001
Commencement of injection: 25...125 o.k. If not within tolerance page 01-34, Display group 004 page 01-40, Display group 002
------------
OCTAVIA
Notes:
I @ 7W Ap A` i 6 A W V W V V VC VX6 wF xC e C C 6 9 6 6 eE s h V E V V w x x Q @ s e e vw ue gD hv WrD Pd V V W @ @gd 6f AV e 9 6 Dd D@ gd hV gD g h WS Pe f VW VV WUqD dXrrX V V d E9 W @ XUW Xf XXU eP sP i 6 8 6 6 p cu q FW a IHUU RrDXQ PDUQ AcX DP DE @6 67 Ci @XX @ @ CH9 6pDcXUrU AQD 6HDD 66 7HX 6UD Ab 6 6 8 % ! 2 2 2 "Bc %87 $!A G @X 63 @ S C $ W DQ9 &#` A9 Y VU 0V4 (T 'E9 FD6 )R 1D
Self-Diagnosis
01
000 at f
gear
not less
for
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 K Readout in display
pressure: ignore
emergency
page
pedal:
page
Engine speed:
------------
------------
01
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 K Readout in display
------------
I 7@ B6 Bi x 6 B W V W V V Vx Vd vX6 w e x 8 6 x 6 6 eE r` h V V v V w w P V Q @ e r e sv ue gD hs WD PD V V W @gD 6f B8 e 6 Dd D@ g@ hV g h E9 WXx Pe f9 VW VV WUpd dXqd W f V V W d @ XUg XW FW esp B rP 7 6 9 6 cu a R V T IHD RqDXX PDUX BcQ DP DS @E BXUqiU Cx @XHX @ @ Cq@ 6XQcDcUqU B9 6HQ 6UUUX 6D B 6 3 Dib " DQ2 W %87 $6A @X 69 2 S C $7 G8 H2 6 &6 Y 6 0V4 (% A '#` )E9 1FD9 !
Self-Diagnosis
OCTAVIA
000 at
test in 2nd
not less
pressure: ignore
emergency
page
pedal:
page
Engine speed:
------------
2 2 #2 # A " " $ 5 3 2 # A 0 # E 2 2 #' #3 A " " # $# 3# 2 6 F 23# 2 2 @3 # # #D AA " " $# 5 5 35 0 2# 2 #G 5 #2 " # 1 C 34A 2 0 D A # # $ 4A E 2@ 2 2 @C # #3% AC " " # 5A 5 35 ' $ $# 72 2 $$ 8 5 0" 2 29 $# $ 7 7 @A 3 #"!49 6 #7 "B 1(A ' &2 A # %# " 3C % #2 "# $ 7 $ (@3 3 7 39 7 s y x9 9 !$$ s3e7 s i3 r3$ g t s q (d (33@ if tB y2 g3@ i# y# y33 r( r 7 q yf y @! i( 2 ( hv #wi u5u %4 #$ 3g #4@ u XR@re X cp I$3$UR I a@S Wwh aR Q39h P W ` V P P I Q P YR Y T T H b
for
OCTAVIA
engine idling
speed rpm
for
pump
pump
Self-Diagnosis
K Readout in display
replace
temperature
consumers up replace
replace
pump
pump
not less
pump
pump
up
------------
------------
01
m e e h d s xm x wt vj o y k f 33 F 3 Fu F 8s F 7 7# !5n 7 $r ! $ # % G 6 5 5"q # 7 # $ F 3 7 ! & 34e 3 3! 3 3 7 $ $4 !l $6 Cf 3e 38 34e 33 %k ! !3 $%5 C53 Cr %4C & 6! 6 @ B5$ 43 3 7 $ 2 ( 3g$ F e 3 7 gm 42 $4i $3 ! %# $ B &) 7 46 # $4B #" ! !# # t 2 %4! 6 57 3 3%F'd 3$ 3# 3 8 3 746 7 o$ C3 $48 !d 2$)"4 #p$ Cp $ ! ! # %56E 5d " 93 3 6 &3 g7 53 $e #3 ! ! %f f m @ S5sg fg P3 V6 Us de S h2t hU t# %hg !4 3%8 3 3 %"A $4 !d $C C5 # # $ C %"3 6 4 4) 3B8 $4%4%5% !%%" $2 C)2 % 1A !4%% C $ E G D B 3$ 5B4 $$444 ! $5C CC5 $ BC 4 G"8B 3Q 3B 3 BC $ ! $ C %" $ !4! $4 C4 # # %! 6% 6 1 34$ 3 3 % $! 6 $3 #U $ $ E 3 14""5" F8 !8 $ $ %% E 5v 5E G8 3BC 3V 3 X $ !@ $4F C%! # # $ $ % 6C 6% @ ( h !W Y 8 & @ & % 8! 3 h $ # ! %$ 94T Ih 146S 3 3!V ) $ '3 c 2 4X I BP% )IR $#`I 7 $6Y #DP 2) !S (V $a ! &$ bh 2u%h H 4 & $Q #3 !Q % 4 8 4B ) % f W P v w bA d8 U dA c8 cA fR"5A dC4wR fA4AaR S!Q X( c434BV Q4BQ e S$ c$ d"aB" c4 W4I W Sw V gx V3 Sc V448 X U pBS h3 h5 h)% sVI YC45W i4P q%4BByu r!W thT H ` Y Y
Read measured value block Read measured value block
------------
01
rpm
rpm
-----------
engine idling
speed rpm
speed
Test
quantity
at
quantity (actuation control in quantity rises in time (pump is operated) or constant system memory supply system Final control
drops
piston movement sender control to control unit position rises in time (pump control closed Observe display block only pump
pump
Self-Diagnosis
K Readout in display
K Readout in display
temperature
temperature
replace
consumers up replace
attempt at
replace
pump
not less
pump
pump
pump
up
quantity
piston)
system tester
replace
OCTAVIA
valve
c Y G G Y C B I C B C U Y I G ` v e e c R R G B Y tG xt qA U Ied G u RVY Vc SP Ru GS YI uY Rf c c R G I Y G I wY C yY vY vA 7G rG c R u Y G C B @ A i `R t u R G I Y G Vg vS 5 e@ eS cR c RG RI Grru SG Y Y Y G G BY r5 rS VR Y t qI Ud I IY9 GGT ue RS GG YT YY uVG RTrA RI GI c c R G I S G S wY yR vB vY 7I Vc VGX7 rG C P h Y GY IP5 YI G7 Idd SG G R TTrS C B f A 7 i XR V 5 C B C @ B A A e GTt IPVV9 c YXG GV8 IT SY R G Y I T b Vi E ` 8 7p QPG UY GerG IYX9 YYY SIVV6 GY IT R85 RP7 SP IVu GT GI8V I I9a TGG TI TpT Fq VxGT XVa8 Pq Hq PgXXT Vf Pqg VT8q E D8 C8V B8 @8 C B A @ 6 7 7 9 58 3 2 9 P "S W9TV88 "7 Vu4 VVVV8 A !X8 pd6 P81 V9q 6 TXT 8V 7 V &#T $ $8T2 $VVPq )ST8P q" '$dV89 %YX (@7 0Vu2
Edition 12.00 S00.5113.53.20 rpm Read measured value block
for
OCTAVIA
engine idling
speed rpm
Earlier
too cold
commencement
commencement valve pump stops too late commencement Earlier too cold up valve pump stops too soon
Self-Diagnosis
commencement
up
K Readout in display
ratio
by control unit
not less
commencement
blocked
------------
valve
------------
01
` H H d S D C P D C D V ` P H a g a E f f H d SH S C ` gB gB wh yw tT V PfB H x SW` Wd Tp SP Hx `P x` ST d d S H P ` T P i` ` 8H uH D d x S ` H S i D C A B r aWQ g ae w x S H P ` H ET fA f` d ` ` ` d SP SP H TH H H CT uuH WS gC g` `Q wx tg VS q P`` HHUe xfuH ST HeY8 `U SWP Hx `` x` SUT d d SWW HU P T H i` S 8P uH D Q Wd WHW H` PQ `P HP Pe@ TH ` H S UUui WH YS W DU C h B r @ g i @ D C D A C B pY B f HU` PQsH d `` Hw TW S H ` P U c Wr FWWU at 9t 9t 87 RQYU VP HP` P P@U H` PU SH SQe TQ9 HfuS P`Y@9 ``9W TP@ P8 HWx UHW6 U9Qt Ug QA Wh Qtp Gt WyH YWbH WU9s Q9 Ib FY9 D9W C9 A9 E8 D C B A 8 8 @ 6U 3 @ !t ! #T !H8 # X%WWeWeW5 Wx B " se9 ! 7 UW9@ 9Q $4 7 9 '`Ue2 %9U %eY9 0TU93 ti7 &`YWuW (YHWWuW9 )`3 1%uuQ UW
Read measured value block
------------
01
models
rpm
-----------
engine idling
speed rpm
too cold
commencement
too cold
Self-Diagnosis
commencement o
up
K Readout in display
ratio
up
by control unit
not less
commencement
blocked
OCTAVIA
OCTAVIA
Notes:
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Self-Diagnosis or gear
01
at
throttle for
test in
engine
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read measured value block rpm K Readout in display ratio
commencement valve
valve
control
commencement commencement up
in display block
too cold
in
commencement
by control unit
speed
rpm
------------
------------
01
Notes:
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read measured value block rpm K Readout in display ratio
------------
X P I b yttV x ah a V X V P d Xh h I Y d Xyb VX h aV V beY aQ V hH h ac x x a V h b X Rh h X h DV ex tV r x h V h h V V r a V s X V h s `Yb VY Xt h X h h b huh Vw aC ht Xq bb ua bp ieV et b GV fV y Vc X x h V h X c h a y y x a V b VX XC hQ Veh Xa b ch P YX V a b X w yX V dV hVe X ah x x x Vp XY hu Ve X bc h h V ahg VcteetY aX X Rh c ew g yub dcF D Dh Q td e q r v X X V h b u s XFc Rw TeC pYG SF DV `cc dtveh VVV XF XecE Vcp ah atYg bww VVcuF Xhg hctbD bYwF X Vc chD cX ee YwD Uw ee geY fe YF RY SF TC QF PF H Q P I C E AFeeFe egeegeD ( ( ! 4 3 9 8G %X! (F 'YYgF5 g! #5 !ae I X !8D 'ee !Yu ce w6 eFcE &F eu"F 8! eWc 7 tc@! )e%F a c# eFE 2aH5 cic$ 0Yee# 1V #G $ C
Self-Diagnosis
OCTAVIA
at
test in
not less
engine
commencement valve
valve
control
commencement o commencement up
in display block
too cold
in
commencement
by control unit
speed
rpm
------------
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Edition 12.00 S00.5113.53.20 Read measured value block Read measured value block
OCTAVIA
ignition
ignition
Self-Diagnosis
cable
cable
cable
cable
------------
------------
01
01
------------
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Self-Diagnosis
OCTAVIA
ignition
on
pedal monitor
available at present
Dis la 2
and
pedal and brake pedal not depressed pedal depressed pedal depressed pedal
rake
closed
pedal
opened
pedal depressed
pedal
opened
------------
# $ P F 1 P T 9 r u s i u qyp ror y| mo 0 ole t qn we l0 o q y& oo r ~$ r o v o mq| mr mm6 nw lu no mlw pmr p ow u| rmoe on9 vrq o| qr ro u r F oo otpb mpb qp n tn! % o# q m no tx nq n pb # 0 D # & 0 D ' $ # # ` W2 '#F Q$U Q$ ## $(ts #%D 2'f # &5 0y $y #0 ${U 0r G0# G&f Q #t # 1P # # 0 & (~F (m0 `$ %m1 f !F f )# %P e 04 &4 #$ 1# F$ $$ #g 1 0& $ # 0 0 1 % 64 PP P d Q2 2$ 0F # 0 D G4 0 6D 60 @ P( d C 0$ $g()( & AD)) Ta P()G 3 'G) 4p) $( & $ # I3)( 0y $v # D # m r r 7 S# 'y QmDo $(%l #nd 2$w #n $f(mpt Q{ G1pv 0o $ GEf $3 # Dr $m #b 2 #2t $k 0wm $ 5m( (# (o )z( y fn 6}q @r 6r Po po & ggtt y#tg %g o yq Eo po q4tt r r${m oi qt q w q}f r qe ro vo o }tp 7opm w{ r p tw tn rc u frj (o fmsm (tml hmpk Gm p iGmmt # & & ` S0 ' 4G G #G DGG $ 2q $3)s $ & # #a $0 #Y D 0 (# VD TGg 94 6g( E )3)( PE X W#(h U3W S)Y( # ' Q((Y ## D& $(G 2G(G 01 #(e #x 1(& #G( & DtG 0Y $G #f 0G &( $ ( 60 V3 I P( )(G T# 9v3 '$g CY Hhr 'd 43(( 0g$ &7 01( &G(r &G# # D(EG F$ $ &y G& #()2(H &# 0P(3)G D#( GY 2s 2G3 (G( (Fq )U$ 303) Bf )$ E1Y 7Y 5 A))((G 8 @b 9 6 6 6 6 6 6 6 6 "tq '3 4&3Y &6 $w #$ $') 2p 0)%3c 16v ( %2( %f ! 3b )D) 7 t
Edition 12.00 S00.5113.53.20 x x Read measured value block
OCTAVIA
if
engine idling
of
state of
if
less
less
Self-Diagnosis
or
off
able
or
able
------------
------------
01
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Read measured value block rpm -----------v accelerator and brake detected test brake pedal coolant on up
------------
01
of engine
speed
engine idling
speed rpm
if
speed
engine idling
on
air
pedal position
state
state
air
Self-Diagnosis
K Readout in display
state
temperature
able
up
not less
state
set Repair
OCTAVIA
x y f s x v u u w x x u u u w h w w x y f x f f w u p u h w w w x u y w s v p w x d d u n u n u d w k q sw x vd uu u u y d dv u u u w w x d p u ud u w w v k v w hr e d y v u tr wp g TId Xx 8yf 7uv 8dd FRne Fk 8d Wv Wu 7e 8e E 8 Ff H 8 8 Pv A I C Pd W A F A Dw Qp Rvg Q 6D Rf h Q 6f Thk Hsl Xu 8wx 7l 8xm Ev 8v Wv WAv 7f 8u Ey 8 F H 8 PR I Pd Cv C 8 P I 8 8 A QdPv R Q 6 Rp Q 99u 6y Hr Syg A Av E E 8 Y X C Re @r 9e Axr 88 Avd Fx IQe 7 G9fg C8e Aue 8d YGI Eu PF@ A8 IDI 7v GY c I 8 DD RD@l Rx RX Qp @8 9f Q @d e T H Sm A F A Ql 89Arr XI 8uF E8 Ffg FFA 8ADe H@D He Ive 8PE S Iv PFoA 8u W W8 7 P@R Pf 8v Iv ED 8 7 c C I D D QI Rq Hr 8e 7 E C @ a8 H8DQ 8AC A8DlC IlA CPe EW XII 8QY WU8 88 SR AGF E86 IE F7A 88 PPD@H A@7 PH PD6 Ch AD E7 A@8 Ci E E H PDg f Dd QAmD RQ 6yH 9I e HwP IuI AXD IAe FQ@8 8wF 8@S CPclP XV A86w IA8 CEu EFC 89 Wx 8W IP@A PS6 8G H A8 PI Po E GF 8 PI F 8 8 DI8 DATC Qx ewA Q@PG 6RE e eD @F 6E Hf 8Ry8 IhH 8AX AFf7 FDEq 8E8 8 87A YIQ 8wPc IDS C@@Q IIaQ AQW SEP FQ@A 88Q Fg AH Pn8 AeE EQ EF C9PA IP PA YE A I 8 C D8@8 D8e DA QFS RQUDY QQE @A8 9F@I @@8 USI @DTDD Q e 9E 88R A7@lY 8wI 8u9E 8@D9Tf WfC F88 8QC AAA SPIv AC8 FA 8FE 8H PII 8v@u G8A W@d WAF 7E ID6PY SF8 FI EP8 IP7 F@DQ A7 EE 89S Am Iu 8@ S A F 8 8 8 8 D8gF DQ DI RII RADPG QE8 VEA RA @@I @6v 9F VP8 R9F 6R R 8 A C 7 E I 8I SA A8 I@I 8@P7 8F WA SI AG FQ H S A 8 8 D R7 R 9G @E T@R aQ a A 8@AI@@ HTR9@Y 89IPC9g 8jPPD Y@8QC CFP9EP 88IP FRP 8IR GCF8 EFDI F8FD 87v IEd A8P6P HDPC 8IF WQI FQP@6 ETCW EE@y A@IG ICF PFI X9F APF ET9G C8P 867 WC Ec EW E8 8D6 Aw A@ FC CP I F 8 A F 7 G C DC8I DAF DC` VD@6R Q88 R7DD 6AF bBPA 9Q R R @P H8X X9a6Et 8AAu AG@FC 898Tf 8EIPD 8PIDA 8V@ AAQ IP6AQ CF8P EE7 88E WSA AC@Q 8C8 AA8 8WP@9@D FY8 8EF CAD 8QD@e 8Q6 PAd HD@ EPG Cx PE8 Ih H PD8@C F8 E8 SC Ac CE IBD 8@D 7 PA I FD 8 G 8 A 8 7 P9 D9D8PD9i DDDPF D9R DA DQ QGD8Pe V8DR99 RGS RCDD @D9IPD 6S@@8 RPa Q8 @@8D6 9P7 UR @A 9@PQ @@96Q @C # 2 4P 3 36 DD@D @E !F PDr@T !DDP #S@@D6@ !AID DE6@6D@@P #I6 FC 8PD "DC DW9@Da !36T FDp DR 6DBQ q R 9T '$EB99D@ %PP99r@T %@8D5@9s %F99DP 0F86DTB@ GAPU (@%AD99D@ &8I9@@ )8@@6@@@ 1@@F8@@D9T Rp P 9@D 9C
Edition 12.00 S00.5113.53.20
for
OCTAVIA
The
The
The
> <
he
engine idling
> <
he
> <
he
Self-Diagnosis
he
not less
------------
------------
01
v g q v g y g g r e g x y v g y e g g v x y v e q y v j x y e g j j w r y e e g qx y e ww vx h n g yv y g g j vy x hn w v y iy x x d n j wr u UPe YPe 9ip 8vxf 9@h GSx Gq 9 Xo Xo 8 9 Fe 9x Gw I 9v B D X B B Er Ry SRe Rx 7 S i @v Uvp Igf YPe 9y 8h 99 Fgf 9 Xx Xj 8nf 9w Fv 9 G I 9v Qxe P Q QQ B D 9 9 9 Rv Sxj Rm 7ej S S 7 Ik Tfh BA T BB F F 9e ` Y Ev Se Rx Afl BBv 9vn Bwj GxB PRp 89 HjU DxP Bvf 9 `H Fmf QGAj Bj P 8d Hd df F P P F 9 EEe E SEx Se SY Rh A9 @dE AD Av Ao Ih Bp B B B B 9@ylfk YPh 99 Fg Gxf GG 9eE I` Pe Ie 9B Te Pv QGn 9w X XEn 8Ug Q Q9j 9P P Qv BB Ff 9 8 d D P E Re S A A Ip Fh 9 8 9 Q 9 D I9V9 9BF B9E@9 PRg Db@P FA8 YP 9R` Xw7p` 9mE TF BHG F99 PFh G 99 Qx8 Bo QQdf QE7v DA9 QjD FS Df QG Ff QP G B g EA9 EE R9R Sj 7S f Ie P99 BY` PBU GvP 99i 9AR9 Dn7E YW B@xE PBD DF7 FGD 9lA Xy 9X PG Q9AT 9H I Bf9 QP Q9 FF HG D QpQ G 9 9 EP9 EA Riy fEP RAAQB 7SI f 7S f I9 9SER PiG 9BY BGDd GEhG 9QFB 9ES 9GH `y 9I PE@F DAAR@Qk P@EI BRP TFw GEAh 9A8P Gh QRv BX Fj DQG F Fe P QU9 `F B P 9 D F D EBAhQB E9@w EB RGT SR9 Rex ABQ @BAx APAG VTP R AEfQX R f 9yR B8I 9vP 9I 9Ag8 XBAg G99 9RD BBB TeR BjB Gv79 9G9 97T9 QAPP 9`7 HBB XR9 XDH 8RG PEApQEv BDe TG8 GAR FQ9 PQF 9A9 Gr B8 F 9@T PEf 9AQ T B G 9 B 9 Eg SPP SP RF9 WRv S`9 A9 ARQ @ WR SQ 7fEf S AG 9 9 D 8 F P 8 9F B9 PS 9AQ9 9G XB TF BH I T B 9 E S8 SAE U7EP b B 9BBv IUHP 9@PQS 9QBBQ `HUDX DGQ@FQ 99P@ GS9@ 9P9 HDG9 FGGE GGQEQD 98B PI BPbR IG 9PG X7F G@DAR F9QA@AE FF D9ED PPEA Q8EH Y9 9EF BEP FP D9A7 99 XkQE Fd FX FQQ BAd 9a PAE 9 DD P G G 8 Q@ H EBI E9B ElGD WEQ@QBCE@fE RFGE S8D A9R7Q 7vB cCQB @8 S AR Ue I9Y Y@bTB 9SA BHAGDf 9@9U9h 9FBb7 9QPw 9WA@@7 BBQD PFX D9EP FAGR 99F XTB BF@G 9D9 BB9 9XG GBR 9F9 DGR 9bR 9R7 IH FQH Dy QGS Pi Fu I QPEE GT BfP F9 TR BB DP 9E GA 8 QQCG P GQ 9 B G B 9 D 8 Q E@BAPQ EBQE@p ESA7 EEr E@GE Ed ER RmS W9EPE SPQ SBQ 7B9 AE@PQE 7B8 7TAAQ S9 R9 AA9E7 @Q8 V AB @AQD AAP @G AT 4 4 4 AF "G D "EEQ !R !EAEAE@7 $9AAE7AUA "BdU $GbAAAA EF7A7E6A@@E SQsU !SQEE 9QE # RE@AEAq !VDEA "EQA` !AQ79 EF ES 7@HEU DA@QEq %F@AE EDA S DQ (95C@@EA &A9EE@t &G@@Q &@APAQ 1F9sUCA HBQV '9T@A )GHAAE3 09SAA77 2&BR EP@U Q @D
models
-----------
------------
01
The
The
The
he
engine idling
he
he
Self-Diagnosis
he
not less
OCTAVIA
OCTAVIA
Notes:
u H TQ VT h gs q yh V T Y V d g pc bb TY Vi eXT Vad r i Ye fc i T X g Wp W u V V Y T Y T Y qT dV q y 9pWa 8Y 1V 1e 1b 7) A 8 2X 8 ) 8 7 x xc G v cc W PW s V s R pW3 V0 q rac2 Iw Q3 b b Ydc7p i hYa$ Yp eXWWcp he V TcI f V Y YpP ` Vi T1 ay a a gT Wap S R QQ I' P HP CA @ 9( 8T 1u 1 ' 8 '( ) 8 7 7 0# 2 1 @U" 2&rp 7pp5 %t '5 7W#65 7 0V ' $ BV BQ &4 F8% 38#I D0B% EIq G)) 3 3 T# c 0 !# I " 6 % p0 & p e pp & %
Self-Diagnosis
01
for
gas
engine idling
recirculation valve
speed rpm
readout
readout
for
sensors
engine on
not
and
as
readout
as a substitute value
If the engine is cooled down, the temperature readouts for fuel, intake manifold and coolant are by necessity approximately identical with the ambient temperature. If one of the readout differs significantly, it is then necessary to test the appropriate sensor.
------------
------------
u d u x ` i p a q U d f e ep a Wg c h l Ys Y v p ` a cl d U q x up ap hp ha ` v p rp dd ` p h y c p uwh `n `t aYp ps tu pd h a p p ey c dc be d` bh y wu w h p h d uu xdh gah uw `h phrh aig Uv hru pia hs pt qj p h hr rwU rh s fuV eh U h W q k vd r p r j p y r id wi V d uu xU gaq u `Yi pa ahp awW hgq pu hu p qv pgp hwV h rat rv frp e S x m W gp wp ia q s gd uv hp p qhh u rp V `h ar f cq d wh `wYrY aiY fwb fh cib p Ub d wrw xx tgY prwrp p pia hw rh sr Sb `Yiw ` arwY a fV cYrg c c dU 5vwr3 BYW 1y@ Ehb 0h&rYiP 2tg6 8` %S8 '@$ 81 DYe 1brX 1ba Cb3 0' 'V 1wr6 06 0' D@gP 'hY4 8whr1 0$ 1 8 F)YX 6xP 6E 6u% 6wY0 Hhrwd 3dbY0 78Y" 40q2 G'wr) IYv2 A9 7 & b !Q b% # ( Y5Y& R& & 0 1 & V
Read measured value block rpm
------------
01
Notes:
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
------------
at
speed
rpm
test in 2nd
Self-Diagnosis
K Readout in display
control on
Repair
Repair
pedal
and
limit on
basis
recirculation
basis
speed
Repair
not less
test and
incorrectly set
OCTAVIA
OCTAVIA
Notes:
b W W ` BP R C h S 6 F s GR C 8p E bU 9 9 AT B CS h X R H Eh eh @ DA bv WP ` CcS PR PC B R R TP E U b f F B R a E r 4a bR WYP Bb BV CP RU VW RF P C P R Eb Fb rtR FB DAgR a YW Yy qP U b bR bP p r WW `FW C@ WR BPF RTR CR h6 PIR RQC PvT Rc S R P TbT TP AY W7 P s u9 yh wr qP qr 8 e @ qW S XqY6 R h R h w a b T bqr bYR pI u WWF `68 vX Wb BA7 RbC Cx hCYf PIS RW PAIR RV SX RY7 Pr C Pe TCV TX 8 @ w TR b s ue ytP w` qh r e QC vU pAI@ WX 4 PqR Rb ST hW TYt4 c7 f d Bv CT H Eq F bY 4Y BqxYADc CYQdIT Ht EtYAQA eX 6P F bxqTT` WS `R PY XA VdA RTYdw RD RQC PP TP aeA UqR A8 BdTqQDY B CIg C C HD ETYA EqI E DTA 1 'cVA7 YD1 !TQ TT &PD3 `@ %B 4% qc2 %4 #AG %YA DA9 DT S "DqI R $xYF6 $YAg1 $& )PTYFA FDA hS7 (YTg9 0AX TA
Self-Diagnosis
01
at f
gear
for
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read measured value block rpm K Readout in display
limit on
basis
recirculation
control on
Repair
basis
speed
incorrectly set or
speed
Repair
------------
------------
U 0 G5 QC @ P8 P C R # 5 0T I HP 6 ' 9 E B S $$ # # $ $ $ # # 1# )A 0 V " # " ( ! &FD@& ) % ' " ! 74 ) ! h2& x$$$ g q `# b q w$ q$ fT f$ v f f$ ws bb e$&$ yd i t $ pq$ & R U T 0 R G Q P8 b% C P &# i # 7 # C 0 Iei$ He%$ 6 9 E B 5 ' $ S $$ #iA #@ @ b $ f $$ # # 1# ) 0Fs f " 5 C e e " ( !re &# & e)$ x $` s q i Y a ! u)e 'Da$ Y &f "i ! c q i p aa #h &W gX g f d `a ea b $ Y s h2 fVha eap g xa ws bb& g#$i q `q bi qc w$ q$g fT f% v$ e%b f e& f ed er f q e ydX iee i` i$f ix i u4%a $` pq$f e#W ba $b t sY a
Read measured value block Read measured value block
Notes:
------------
01
Notes:
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
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010 at
010 at
mbar
mbar
test in 2nd
test in 2nd
Self-Diagnosis
mbar
edal
edal
mbar
not less
not less
OCTAVIA
OCTAVIA
Notes:
U rW W h q` YY YX hS d d stv SY tu V idv U PR C% 2w 6gR %&fS 'pP' 61 B@x 1Y 1`0 '5 Avy B0TS 'wv 6' 0) 1 ( $ Db`" 4S HY6 Fe2 5c E04d GbS I44dav2 81 9W 8v & qf# & 00 4 4& 4& P 3 % 7 W !P
Self-Diagnosis
01
011 at
test in 2nd or
gear
not less
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read measured value block rpm K Readout in display ratio o.k.
valve positioner
speed
readout
readout
rpm o.k.
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OCTAVIA
23
OCTAVIA
Components A to E are not shown in the exploded view. A - Relay for diesel direct injection system (J322) On relay plate page 23-3, Fig. 1 B - Relay for glow plugs (J52) On relay plate page 23-3, Fig. 1 C - Accelerator pedal position sender (G79) In footwell at accelerator pedal
D - Brake light switch (F) and brake pedal switch for CCS/diesel direct injection system (F47) Mounted together on a bracket In footwell at brake pedal page 23-3, Fig. 1 E - Clutch pedal switch (F36) In footwell at clutch pedal page 23--3, Fig. 1 1 - Injector with needle lift sender (G80)
OCTAVIA
Fuel Formation/Fuel Injection 10 - Plug connection 3-pin For engine speed sender (G28) 11 - Plug connection 10-pin For fuel temperature sender (G81) For quantity adjuster (N146) For modulating piston movement sender (G149) For commencement of injection valve (N108) For fuel cut-off valve (N109) 12 - Commencement of injection valve (N108) 13 - Fuel cut-off valve (N109) 14 - Fuel quantity actuator of injection pump With fuel temperature sender With quantity adjuster (N146) With modulating piston movement sender (G149)
23
2 - Diesel direct injection system control unit (J248) With altitude sender (F96) 3 - EGR valve (N18) 4 - Mechanical exhaust gas recirculation valve 5 - Coolant temperature sender (G62) 6 - Intake manifold temperature sender (G72) 7 - Throttle valve positioner (V60) for models 09.98 Intake manifold flap motor (V157) for models 09.98 8 - Engine speed sender (G28) 9 - Plug connection 2-pin For needle lift sender (G80)
K Fig. 1
Components in footwell
2 - Diesel direct injection system relay (J322) 3 - Clutch pedal switch (F36) 4 - Brake light switch (F) and brake pedal switch for CCS/diesel direct injection system (F47)
23
OCTAVIA
1 - O-ring 2 - Throttle valve positioner (V60) for models 09.98 Intake manifold flap motor (V157) for models 09.98 3 - 10 Nm 4 - Spring strap clip 5 - Intake hose 6 - Top part of air filter 7 - 10 Nm 8 - Air filter element 9 - Bottom part of air filter 10 - 15 Nm 11 - 10 Nm 12 - Inlet connection
OCTAVIA
23
K-
Slacken the bolts -1- at the EGR valve. Slacken the bolts -2- and take off the intake pipe.
Installing Install in the reverse order. Tighten the bolts attaching the intake pipe to the cylinder head to 20 Nm (replace seals). Tighten the bolts attaching the EGR valve to 20 Nm (replace seal). Tighten the bolts attaching the top and bottom parts of the intake manifold to 15 Nm.
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23
OCTAVIA
Note: Use open ring wrench, e.g. 3035, for removing high-pressure line. Cover over the openings with a clean cloth.
Remove top toothed belt guard and cylinder head cover as well as vacuum pump. 1.9 l/50 kW (SDI) Engine, Mechanical Components; Repair Group 13
OCTAVIA
K-
K-
K-
4 & & & ' ' " a ' & & ' # ( & & ' a ' ' 4 & 0 & & ' 1A 0 & 0 & ' ' ' ( & 4 00 & & & ' b ' ' )' ( & ' & & & & ' a &' 0 ` 0 & & & ' & 0 7 ' ' ' 4 ' 0 & 0 & & Y ')& A 0 & ' ' ' ' 9 4 ' c@ # 0 & & & ' & ' @ () &)% & X ' ' )))# ! W " $ 7 4 @ ( & ) 1 & A & 7 '1 ' '1 ' T) C U H C) R G D D H I)))) B I (1 & ( ") ( ) & ' '& ' ' ' 9 4) & 1 & & 0 & & Q @ ' ' @ ) 7 # # ( 1 &8 & C 6 ' ' ' V ' # 4 4 ) A ' 3S 2# " ! & 5 1 ( S &# 0 S ' ' % #@ & #)1 PF ) ))E ! $ ") $ " )1
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23
------------
K-
K-
K-
Note:
Notes:
The valves of cylinder 1 must be closed and the valves of cylinder 4 positioned at overlap.
If it is not possible to lock the injection pump gear 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 gear and only now position the crankshaft at TDC.
Always moisten the locking pin. Use a mirror to facilitate inserting pin.
Use the locking pin 3359 for counterholding the injection pump gear page 23-10, Fig. A13-0052.
OCTAVIA
# % ' # # & E ' & # ' ' C D B & # # % & # # # % & # # # # & ! F % 'G ' @ 4 4 7 5 " '8 (! ( A #8 " #3 # #A # 6 $ 9 ! &( '! ( # # # 1 & !$ '2 ! # ) 0 & 0 # 0 ' # ' # # % ($ " 0 # & % # & % !# $ ! ( $ !
On no account slacken the central nut -2- of the injection pump gear otherwise the basic setting of the injection pump will be altered and can no longer be set with workshop equipment. Note: On no account slacken the central nut -2- of the injection pump gear otherwise the basic setting of the injection pump will be altered and can no longer be set with workshop equipment. -----------------------
OCTAVIA
K-
K-
23
23
OCTAVIA
K-
Align the injection pump gear in the middle of the slots -arrows-. Lock the injection pump gear with the locking pin 3359. Slacken the bolt attaching the camshaft sprocket about 1/2 turn.
Note: The adjusting straightedge must not be used as a counterholder when slackening and tightening the camshaft sprocket. Counterhold camshaft sprocket with special tool MP 1-216.
K-
Insert puller T40001 with hook T40001/2 -Aand T40001/3 -B- onto the belt pulley. Use the open-end wrench -C- as a counterholder and detach the belt pulley from the taper of the camshaft. Tighten the bolt attaching the camshaft sprocket so that it is still possible to turn the camshaft sprocket. Check whether the TDC marking on the flywheel is positioned opposite the reference mark. Fit toothed belt onto injection pump gear, camshaft sprocket and tensioning pulley.
K-
Tension toothed belt. Use the toothed belt tensioning wrench (e.g. Matra V159) with setting wedge to turn sufficiently to the right until notch and raised section -arrows- are positioned opposite.
D ! 2 5 G F F % S ! Q G T R ! 2 2 $ $ 0 ! $ 2 2 I % 0 8 ) ) $ 8 8 D ! $ $ $ $ 8 % % ! $ P $ $ 0 ! 2 22 2 5 % G F F $ $ $ $ 2 8$ 81 % $ $ $ 2 % ( !$ 2E 2 2 % 0 "C ! ) 2 $ 2 2 5 G" FE F" % 6 ) 2 % 0 ( A $ $ 2 $ $ $ 1 ( ' & 8 % $ % % 8 D ) H $ 8 1" E $ $ $ % ! ! $ $ D 7 ! $ 9 @ 2 A F A 8 D " ! 2 5 G" F F % ) 9 @ B A A 7 3 $ $ ! E 5 4 6 ! $ $ 1I $ $" 0 "% !H ! 3 $ $ $ 2 1 $1 8 ) $ $ $ " 0 ) # ! 2 $E $ $ $ 2 (" '" & % % " !1% " C 7
Use the bolts attaching the injection pump gear only once as these are stretch bolts. Note: Note: T T T T /
-----------------------
OCTAVIA
23
# ( i A 3 3 8 m n o 2 F 2 j $ ( % i i 1 0 ) 2 l 3 3 2 6 B i i 1 0 ) 3 2 2 % $ i i 1 ! 0 ) F 2 ) h g e e f f a h a s s ` a a X x b b Y a b a X b h b Y b s y s xb b f a h f h b X h q b Y g v a X h g b Y s s ` ` ` Y b a a b a X Y a X h a b g x b a Y cE y ux h Xb g b Y b f b X a Y w g b g Y q b Y p r db ` ` ` Yb b" a" ` a b a X Y X Y x b a g c a X ` ad a Y Y a h Y w f w b Y cf r sc y y a hg b Y g a b b Y X a Y X a x b b a cg c yd s r y p ak ha h a gX h a g a v Y Y x b h a cg r s y uy y aY h@" vf a h a qq a g b g X a b h g v ca u s s `"" pb ` hc7 ` ` hc" g q"" f b Y g a b Y X b a a b a X Y Q W" I U V V U S I G "a 7X" $ $ $ 5 X (c g #dd Fg 2a 3y Fc" 8 $d (w c d c E te $ v # ( # vd cc 9 $aded $X #h Xc #d dq uiudiu c g dcd ed 9c ( # cc ! 8 %cced idccd ud ddic d $ #d # $g w v c % 9 i ir %ced (v # "X ccicd cc X Dcccv C %hi $cicdd $c a iidg # # 9 g "i $udc (a c # # 2tc ! %ed ccc (P X ( d H # 6 A 3 8 "2 " "T " $ $ # # 9 ( R 1 0 )E @ $ # # % ( " " # " 6 2 ( 1R 0T ) 4 2 3"T 2T 5# % # ! $ % E 7 # # ' ! "7" & " B " ' 7' 7
------------
23
------------
K-
Notes:
The
and
he
OCTAVIA
OCTAVIA
Test procedure -
0 9
10
K-
Do not continue with the test until the coolant temperature is reached. Models 07.00 K-
Models 08.00 K-
Note:
Provided the check reveals that the commencement of injection is within the specified range -C-, it is not necessary to carry out any new setting. After replacing the injection pump and the engine control unit, the commencement of injection should be set to the mean value.
23
Connect vehicle system tester V.A.G 1552 and select the function Initiate basic setting page 01-20. Check readout in display block 7 (coolant temperature). Specification: less than 73 (equals 85 C) Commencement of injection in display block 2 is dependent on the fuel temperature in display block 9. Specification: Figure - range C A - Display block 2, commencement of injection B - Display block 9, fuel temperature C - Specified range for commencement of injection Commencement of injection in display block 2 is dependent on the fuel temperature in display block 9. Specification: Figure - range C A - Display block 2, commencement of injection B - Display block 9, fuel temperature C - Specified range for commencement of injection
------------ 23-13 ------------
23
OCTAVIA
If the commencement of injection is not within the specified range: Switch ignition off. Remove top engine trim panel. Remove top toothed belt guard. Inspect tension of toothed belt. The markings on the tensioning pulley must be positioned opposite. If the markings are not positioned opposite: - Adjust tension of toothed belt: 1.9 l/66 kW (TDI) Engine, Mechanical Components; Repair Group 13 KSlacken the two bolts -1- attaching the injection pump gear (counterhold with locking pin 3359). Position a ring wrench on the hub nut -2- in order to hold the pump shaft tight. Slacken the third bolt attaching the injection pump gear and turn the pump shaft slightly: Turning shaft to the left commencement of injection retarded
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! ! ! ! ! ! ) " # # ' ! !! # ! ! ! ' ' " " ! ! !$ % # ! ( $ ! $ ! ! " $ $&$ ! $ (
Turning shaft to the right commencement of injection advanced he Note: The e Tighten the new bolts attaching the injection pump gear to 20 Nm and then tighten a further 1/4 turn (90) (counterhold with locking pin 3359). Note: The Install top toothed belt guard. Install top engine trim panel. Once again check that commencement of injection corresponds to the specification.
-----------Edition 12.00 S00.5113.53.20
OCTAVIA
15.9 C
7 16.7 C
K-
K-
23
------------
OCTAVIA
Specification:
Specification in field A applies to temperatures of 0...50 C, in field B for temperatures of 50...100 C. Example:
Connect test box to the wiring loom to the engine control unit. 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 23
For t
Test the following cable connections for short circuit to positive and to negative and for open circuit. 2-pin connector at wiring loom, contact 1 2 T .
13 25
For t
Test the following cable connections for short circuit to positive and to negative and for open circuit. 2-pin connector at wiring loom, contact 1 2 T .
73 54
------------
0 7 " 0 " 3 0 " 0 2 7 ( ( ' 1 0 ' 8 0 2 " 8 3 2 8 % ) Y 7 # " 7 1 0 0 3 # ' X U 6 b a U W V 0 # 0 3 # "# 0 8 E H S Q G C C (! # 0 Y 1 00 3 0 0 0 %D % )A ) 0 0 " 8 " ' 0 7 ( ) 0 " ' 3 8 ( d S Y G "8 3) # " " 1 0 8 8 " 3 ' " (% S ( S Q H S ! 03 #8 22 2@ # 0 8 7 8 " 0 " 3 0 %' % ( @ 0 72 '0 # 8 8 ' " ' 8 %' % % ) ( Y &4 1 08 '&&% 88 0 " 8 3 2 8 0 0 !8 G ) 1 3 W ) 0 0 " 8 " ' 0 7 8 (8 ) 09 3 " 0 " X W 0 @2& 52%& 28 78%&& 0%&&&`&%% "TRF&& 1 2 "% " ' 8 0 0 8 0 0 3 %' 0 )%%2 (9 &2 Y$P! Y$%$% Y&$% 0 00 #0 "2 0' '' 0I 0&% # 2) 0 " %) )&0 ( ) ( ) 1 $B$$ 9 $ 3 W ) 0& " 0 ) 0" 2&% 0&%% &% ! 8% 3 # 7 8 7 0 0 " " %( %0 %$8 )2&%%&5 W ) &&% @%' @&&2 @ 0 2 ' U&R&%& &%% & b U 2 A8 a a A B2 G @%%$&$ 9$$2 0 Y&% Y 3 0 0 0 # F U&9!%% &%9!% && C" a7 P" ( ) %&%& &$&$% % 5 & $!!5 @ Y%%&&% 7( "7 2&& "8 0& " 0 % ! (8 D !0 A A !8 $8 $4 &9 t t d u h24! r%$%%& d&' r%& v e q r d i h e f x( & y" " p w92 c g% Y 7T9 #8 "% 7 1 0 0 3 # ' X 2 Us 6 b8 a' U W V @ R 7 "0 0%%$9 05$% 8gq #&%$& 0$& 2 3 %d E5 (2%5%$ H9 S%% Q% G C C A D & $ P 9% f #&% 0 3 8 0 0 " 8 2 6 1&sf 3&`f& F&B 09% &P &% #% # " ' 2&&$I!g 4B95 %&%$& )2 ( &f5 &$9 %$ F % $5 5$$$$$ % %2 ! %&
If If Special t If . t 4 f. and . . required I I 4
-----------------------
OCTAVIA
23
23
------------
4 % 9 7 9 4 & 1 % & ( % 5 0& ( % % & % % ' 3 ( 62 # & ) 8 $ @ 63 3 4 & 1 % & ( 2 ! ! 5 0& 0 ( % % & % " ' '" # & ' ) % $ $ $ 3 $ $ 3 0$ '
Fuel Formation/Fuel Injection For t
OCTAVIA
Test the following cable connections for short circuit to positive and to negative and for open circuit. .
2 3
49
For t
Test the following cable connections for short circuit to positive and to negative and for open circuit. .
2 3
81 75
------------
OCTAVIA
23
recirculation
recirculation
The test of the exhaust gas recirculation is performed in function 04 - Basic setting. The exhaust gas recirculation valve is pulsed every 10 seconds so as to produce extreme values for exhaust gas recirculation. Special t t and
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
Connect vehicle system tester V.A.G 1552 page 01-2. Select 04 for the function Basic setting and enter display group number 003.
0%
K The readout in display block 2 must change every 10 seconds between EGR not active and EGR active.
The following readouts must vary in display block 4: EGR not active -
EGR active -
Test mechanical exhaust gas recirculation valve 1.9l/66 kW Engine - Mechanical Components; Repair Group 26
- Test EGR valve (N18) 1.9l/66 kW (TDI) Engine - Fuel Injection and Glow Plug System; Repair Group 23
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