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Service

Workshop Manual OCTAVIA


1.9 ltr. / 50 kW (SDI) Engine, Fuel Injection and Glow Plug System

Service Department. Technical Information


S00.5113.50.20 Edition 08.96

The Workshop Manual is intended only for use within the KODA Organisation; it is not permitted to pass it on to third parties. 1996 KODA, automobilov a.s.

Printed in Czech Republic

Service
List of Supplements to 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

Edition 08.96 09.97 07.99 12.00

Article Number S00.5113.50.20 S00.5113.51.20 S00.5113.52.20 S00.5113.53.20

1 2 3 4 5 6 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 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 ...................................................................................................................

01-17 01-17 01-20 01-22

01-23 01-23 01-24 01-28 01-31 01-40 01-43 01-43 01-44 01-47

23

Fuel Formation/Fuel Injection

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

Technical data of self-diagnosis


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

Edition 12.00 S00.5113.53.20

------------ 01-1 -----------01-7

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

08 Read measured value block


1)

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.

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

Edition 12.00 S00.5113.53.20

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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

Edition 12.00 S00.5113.53.20

01

01
038906013A 1.9l Coding 00002 R4 EDC

Self-Diagnosis G00SG 1504 WSC 01234

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

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

# % & $    ! "      
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)

Current control unit version Parts List Not available at present

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

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

Edition 12.00 S00.5113.53.20

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

Test of vehicle systems Select function XX

HELP

K Readout in display: -

Test of vehicle systems Select function XX

HELP

K Readout in display: -

X faults recognized!

K The number of stored faults or No fault recognized! appears in the display. no is s

Test of vehicle systems Select function XX

HELP

K Readout in display: -

Edition 12.00 S00.5113.53.20

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

Only if the engine does not start: Switch ignition on.

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.

End output (function 06).

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

01

Self-Diagnosis If one or several faults are stored: Press the key.

OCTAVIA

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

K Fault number appears in the display (example): Press the key.

Press the key.

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.

Erasing fault memory Test condition

l Faults rectified Note:

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)

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


Edition 07.99 S00.5113.52.20

K Fault source with fault type appear in the display (example):

OCTAVIA

Self-Diagnosis

01

Test of vehicle systems Select function XX

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.

Test of vehicle systems Select function XX

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.

Test of vehicle systems Fault memory is erased

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.

Edition 09.97 S00.5113.51.20

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

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

Operating instructions of vehicle system tester

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

Throttle valve positioner

Open circuit in wiring -V60 faulty Short circuit to earth

Open/short circuit to earth

No exhaust gas recirculation, throttle valve fully opened

Short circuit to positive

Short circuit to positive

No exhaust gas recirculation, throttle valve fully opened No exhaust gas recirculation, throttle valve fully opened

- Test V60 page 23-16

Engine speed sender Implausible signal

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

- Detach oil pan and inspect sensor rotor

- Test engine speed sender 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System

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

Edition 07.99 S00.5113.52.20

OCTAVIA

Self-Diagnosis

01

Readout on V.A.G 1552 old Fault number new

Possible cause of fault

Possible effects

Rectifying fault

00522 Coolant temperature sender -G62 Short circuit to earth

17663

-G62 faulty Cable has short circuit to earth

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

Engine preheating not operating

- Test intake manifold temperature sender page 23-15

Control unit was connected when ignition switched on

- 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)

Edition 07.99 S00.5113.52.20

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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

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

Self-Diagnosis

or

Irregular engine

Several stops

throttle response overrun

ment i be

Possible

at high

at rpm

light engine running output

stops

output

output

light

control

Inspect cable connection plug connection at pump

Inspect

Inspect plug connection pump

spect

est

est

est

oil pan rotor

temperature

Edition 07.99 S00.5113.52.20

OCTAVIA

pump

OCTAVIA

Edition 07.99 S00.5113.52.20

  #   5    9 9 ' ' ' # # # 3 1 # & &   )  ( ' ' 7  $ $ $$#   %"   &! "!" $!!"# # !! # # 8        0" 4  "6"" " 2 
Self-Diagnosis

01

on

old

of

Open circuit in wiring or short circuit

Hard gearshifts

- Test signals from/to automatic gearbox

of

Control difference

Commencement of injection not o.k.

Adjustment of injection pump blocked (dirt, swarf)

Poor performance at high revs Engine difficult to start Poor performance at high revs

- Test commencement of injection and set page 23-12

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

Fault 00542 Needle lift sender implausible signal may be stored

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

Commencement of injection valve -N108 worn

No constant commencement of injection possible at Basic setting (display block 2 varies by more than 10 readouts) Irregular engine running, poor performance

- Replace commencement of injection valve

1)

Not available at present.

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

01

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

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Self-Diagnosis

OCTAVIA

on

old

new

of

Possible

speed signal

Implausible signal or

speed signal Implausible signal speed signal Signal too large

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

CCS not operating 1) AC not operating Possible load change jolts

- 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

Short circuit to positive Open/short circuit to earth

Short circuit to positive

Open circuit in wiring Bulb faulty Short circuit to earth

Glow period warning light not operating

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

Engine does not start (safety shut-off)

- Test voltage supply for diesel direct injection system 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System

CCS

1)

Undefined switch status

-E45 faulty Open circuit in wiring or short circuit

Cruise control system is switched off

- Test cruise control system 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System

1)

Not available at present.

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

Edition 07.99 S00.5113.52.20

y C b @ T H R P u G C C C @ b b I 9 I P I D I H s 8 p Y I i v C C I I P R R s C C C C Yx P S 9 S P 9 9 D D R s yp CE bW @E T ' HE Ro P uA GW C' CR Ca @) IX 9f I P7 I D) Id H sD 8( D D pi Yd D R II X H I T T iAs vS xD Ci Cf CP CP `H E AAFFFX X IPm ICw RH PH sFPd C`E @c St IYApC PBbi SrCDe H9f IBAx Ru 9u Pc RADE ml sc FAe Cc Cne If P Ibp PF9Id ICm PAPP Dbj RC FYA9 ftu FS suf CAFoi CW CPsp CBbee ICjoekngnekhgg PPEzi IFCdv Isygf Pqff DSTqr DECS Pgm Eo SYRf IABbf DrtsI RTTd k gkgnge 4e CtCP CRfED C @9S @ HXPC 9I@ IC9 9YH@ RIC RAt9 9 H XEIB@Y` hAC9 sS9 itIG y9F@ CP@ b`AS# @Pv( TFEy @D' ER9BAFBFFt# HPDD RCR PYRD( 9EECF# PI# BEI BTErD h9fX iEX9 Fs uB9x'YEBFBFBEFBF GEBPCFFBP AERvR ABYrXXF' CI@@ CFGfDFBE CfBCDFP FRIP @RRBFI @F ICBIS 9wBGx'3 ITIE PH`P ICdABFR Dt5 IBPD HF8FID s@IG 8CI@ FIRD S@F wBBI@FBBB pRC cFAAFFF6 YBsI 9D RFEBPH RDF IDV EXD@ I SH DYBB HE EA BCP! XBe! fABB9AH FD 9Tr23 hR CEfI 9R ipID vBT98 xYAwBBH9BB hCFFBEFEFBFBBFG AHDFFB( CEA& Cb CAYSBPAF yAA8C Y`pP YH92 bEFFD b7 bBhfY7 IPS ET IHS 9IC IbBC 9Cq RRRBE RAtBBq@ PTBF HAIFQ D ED9 eEtXPf7 B@I XD(3 AE FIFF FFBE FT 8sHfwSU dFXW 8C@EB sESFD2 sCv9 Ae E A  0 ( AB ' ' $FHE8 $g) $C $BSC  HG %FPXEC  2 9 #F BFB! ! ! !FBB   &RHfw 9PA2 IB!E #R@fA r!AA !BE BE@2 R S@ @EBfY4 !"81 #ECC  AY$BBE9 AEP   " CD BBHf@EYfY) eFB "PEiP "HIF (E  "AEAF B   3BFB"B3AA"FF A 3E 
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1)

OCTAVIA

Edition 07.99 S00.5113.52.20

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-

Invalid control unit coding

0111

Preglow indicator light flashes

- Code control unit page 01-22

nator

signal for alter-

Implausible signal

Open circuit in wiring or short circuit Alternator faulty Voltage regulator faulty

Engine preheater not operating

- Test cable connections

01

- Test alternator Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder

Short circuit to positive

Short circuit in cable connection

Reduced vehicle acceleration if AC on

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

Open circuit in wiring

Low heating capacity relay -J359 faulty

Engine preheater not operating Engine preheater constantly on

- 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

Short circuit to earth

Short circuit to positive

Engine preheater not operating

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

Edition 12.00 S00.5113.53.20

OCTAVIA

Edition 12.00 S00.5113.53.20

4 1 3 1 0 & ) ( ' " $ !                   "  0%     #  2%  #     56 %  1 7


Self-Diagnosis

01

Readout on V.A.G 1552 Fault

old

new

Possible cause of fault

Possible effects

fault

-J360

Open/short to earth

Open circuit in wiring

High heating capacity relay -J360 faulty

Engine preheater not operating Engine preheater constantly on

- 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

Short circuit to earth

Short circuit to positive

01237
Fuel

Engine preheater not operating

valve

Malfunction (mechanical fault)

Open/short to earth

-N109 faulty, leaking or jamming

-N109 faulty Open circuit in wiring or short to earth

Reduced output Engine stops Engine stops

- Test -N109 page 01-17, Final control diagnosis - Test cable connections Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder

01265

17810

EGR valve -N18

Short to positive

Short circuit to positive Open circuit in wiring Solenoid valve faulty

Open/short to earth

Engine runs without exhaust gas recirculation

Engine runs without exhaust gas recirculation

Short to earth

Excessive exhaust gas recirculation Reduced output, black exhaust

- 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

Glow system not operating Glow plug system constantly on

Glow plug system not operating

- Test glow plug relay -J52 page 01-17, Final control diagnosis

Control difference (variation)

Injection pump faulty Open circuit in wiring or short circuit

Poor drivability Engine stops Preglow indicator light flashes Jerking, poor output Black exhaust Irregular idling

Upper stop value

Lower stop value

Quantity adjuster incorrectly set

Quantity adjuster incorrectly set

- 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

Short circuit to positive

Open circuit/short to earth

Open circuit in wiring (fuse) Valve faulty

Engine clatters when idling as commencement of injection constantly advanced Several faults may be stored

Engine clatters when idling as commencement of injection constantly advanced

- 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

Short circuit to earth

Poor performance as commencement of injection constantly retarded

- Test commencement of injection valve 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 23

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

Edition 12.00 S00.5113.53.20

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

Edition 12.00 S00.5113.53.20

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

Engine starts and cuts out again immediately

- 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

Short circuit in communication line Fault in immobiliser system

Immobiliser control unit faulty/missing Engine control unit incorrectly coded

No message from airbag control unit

Datalines faulty Fault in ABS system

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

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

Edition 12.00 S00.5113.53.20

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

Edition 12.00 S00.5113.53.20

or

or

of

Self-Diagnosis

No

No

pair

oil

air

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

01

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old or No message from ----------------------on of

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

01

Self-Diagnosis

No

No

Edition 12.00 S00.5113.53.20

OCTAVIA

OCTAVIA

Self-Diagnosis

Edition 12.00 S00.5113.53.20

) $ 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)

9. High heating capacity relay (J360)2)

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.

l Vehicle is at room temperature (warmer than +15 C) l Air conditioning switched on

l Lowest temperature and highest blower speed selected

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

Test of vehicle systems Select function XX

Test of vehicle systems 03 - Final control diagnosis

Final control diagnosis Commencement of injection valve -N108

Final control diagnosis EGR valve -N18

Final control diagnosis AC compressor cut-off

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


Self-Diagnosis

OCTAVIA

HELP

K Readout in display: -

Press the keys 0 and 3 for the function Final control diagnosis.

K Readout in display: -

Confirm the entry with the key Q.

K Readout in display:

When the valve is actuated, a clearly audible change in the combustion noise can be heard (clattering noise).

If no change in the combustion noise can be heard:

- 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:

The valve should click.

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.

If the AC compressor is not cut off:

- Test AC compressor cut-off 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System

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

Edition 09.97 S00.5113.51.20

OCTAVIA

Self-Diagnosis

01

Final control diagnosis Throttle valve positioner -V60

K Readout in display:

Final control diagnosis Fuel cut-off valve -N109

K Readout in display:

Final control diagnosis Glow plugs relay -J52

K Readout in display:

Edition 09.97 S00.5113.51.20


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

Final control diagnosis Glow period warning light -K29

Final control diagnosis Low heating capacity relay -J359

Final control diagnosis High heating capacity relay -J360

Kretjssystem-test Vlg funktion XX

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

& %"   ! !  $    $   !  $#       "        


Self-Diagnosis

OCTAVIA

K Readout in display:

The warning light must flash.

If the warning light does not flash: -

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:

The relay must click.

If the relay does not click: -

Test low heating capacity relay: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder

Press key.

K Readout in display:

The relay must click.

If the relay does not click: -

Test high heating capacity relay: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder

Press key.

HELP

K Readout in display: -

End output (function 06).

setting

est

l Coolant temperature at least 80 C

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

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

Edition 12.00 S00.5113.53.20

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

Test of vehicle systems Select function XX

HELP

Basic setting Enter display group number XXX

HELP

System in basic setting 1 2 3 4 5

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

153 127 255

Fuel temperature: approx. 40 C (is not achieved at a low outside temperature; no specification) Ignore

Coolant temperature: approx. 90 C Ignore Ignore Ignore Accelerator pedal position: 0

Commencement of injection depends on fuel temperature, specifications page 23-6, Dynamic test and setting of commencement of injection Idling speed: 41...44

Edition 09.97 S00.5113.51.20


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:

If the code the

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

Edition 12.00 S00.5113.53.20

OCTAVIA

OCTAVIA

Self-Diagnosis

01

Measured value blocks


Reading measured value block
Test conditions l Coolant temperature at least 80 C l Electrical components switched off (radiator fan must not cut in during the test) l Air conditioning switched off l No fault stored in the fault memory Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Procedure Connect the 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)

Test of vehicle systems Select function XX

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.

Read measured value block Enter display group number XXX

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.

Edition 09.97 S00.5113.51.20

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


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

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

Proceed as follows in order to switch into another display group: . .

higher lower

Press key Press key

Press key 3 Press key 1

skipping

Press key C

Press key C

of

in

Designation

000

Read measured value block 0 1 2 3 4 5 6 7 8 9 10

1 = Engine speed

General vehicle check

2 = Commencement of injection 3 = Accelerator pedal position 4 = Injected quantity

5 = Intake manifold pressure (charge pressure)

6 = Atmospheric pressure (ambient air pressure) 7 = Coolant temperature

8 = Intake manifold temperature 9 = Fuel temperature 1 = Engine speed

001

Read measured value block 1 1 2 3 4

10 = Ignore

Injected quantity

2 = Injected quantity

3 = Voltage of modulating piston movement sender -G149

002

Read measured value block 2 1 2 3 4

4 = Coolant temperature 1 = Engine speed

Idling speed

2 = Accelerator pedal position 3 = Operating state

4 = Coolant temperature

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

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

Edition 12.00 S00.5113.53.20

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&#11 )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

Edition 12.00 S00.5113.53.20

Self-Diagnosis

Designation

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

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

01

01

Injected quantity limit

Injected quantity limit

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)

3 = Injected quantity limit from automatic gearbox during gearshift1)

4 = Emergency quantity (voltage from modulating piston movement sender -G149)

4 = On/off ratio (actuation) of charge pressure control solenoid valve -N75

Not available at present

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

Edition 12.00 S00.5113.53.20

OCTAVIA

Glow plug system

Fuel consump- 1 tion

Auxiliary heater

Edition 12.00 S00.5113.53.20

                 " ! !
Self-Diagnosis

01

in

Designation

012

Read measured value block 12 1 2 3 4

1 = Ignore readout

2 = Glow period (seconds)

3 = Supply voltage from control unit 4 = Coolant temperature

013

Read measured value block 13 1 2 3 4

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

Smooth idling control

014

Read measured value block 14 Read measured value block 15 2 3 4

not assigned 015

1 = Engine speed

2 = Injected quantity (actual value) 3 = Fuel consumption 1 = Alternator load

016

Read measured value block 16 1 2 3 4

4 = Injected quantity request (driver request through accelerator) 2 = Auxiliary heater switched off

3 = Actuation of heating elements No readout

017

Read measured value block 17 Read measured value block 18 1 1 Read measured value block 19 2 3 4 2 3 4

4 = Supply voltage from control unit

Not assigned 018

Ignore

019

Fuel metering control

1 = Lower stop value (voltage from modulating piston movement sender)

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

Read measured value block 42 61 0 24 19

201

70

161 127 255

K Readout in display

Inducted air mass: ignore

Fuel temperature: no specification

Intake manifold temperature: no specification

Coolant temperature: 80...51 o.k. > 80: warm up engine

Ambient air pressure: ignore

Charge pressure: ignore

Injected quantity: 15...45 o.k. If not within tolerance page 01-31, Display group 001

Accelerator pedal position: 0

Commencement of injection: 0...88 o.k. If not within tolerance page 01-33, Display group 004 page 01-40, Display group 002

Idling speed: 41...44 o.k. If not within tolerance

engine idling

not less

Read measured value block 42 61 0 24 19

201

70

161 127 255

K Readout in display

Inducted air mass: ignore

Fuel temperature: no specification

Intake manifold temperature: no specification

Coolant temperature: 80...51 o.k. > 80: warm up engine

Ambient air pressure: ignore

Charge pressure: ignore

Injected quantity: 15...45 o.k. If not within tolerance page 01-32, Display group 001

Accelerator pedal position: 0

Commencement of injection: 25...125 o.k. If not within tolerance page 01-34, Display group 004 page 01-40, Display group 002

Idling speed: 41...45 o.k. If not within tolerance

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

Edition 12.00 S00.5113.53.20

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

road test in 2nd or

gear

not less

for

Accelerate the vehicle at full throttle for the test.

Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read measured value block 0 K Readout in display

Inducted air mass: ignore

Fuel temperature: no specification

Intake manifold temperature: no specification

Coolant temperature: up engine air pressure: ignore

pressure: ignore

emergency

load , system fault detected

page

Interrogating fault memory

pedal:

Commencement of If not tolerance

page

on engine Display group

Engine speed:

Edition 12.00 S00.5113.53.20

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

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

01

Notes:

Accelerate the vehicle at full throttle for the test.

Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read measured value block 0 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

Inducted air mass: ignore

Fuel temperature: no specification

Intake manifold temperature: no specification

Coolant temperature: up engine air pressure: ignore load

pressure: ignore

emergency

system fault detected

page

interrogate fault memory

pedal:

Commencement of If not tolerance

page

on engine Display group

Engine speed:

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

Edition 12.00 S00.5113.53.20

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

Edition 12.00 S00.5113.53.20 rpm

Read measured value block

engine idling

speed rpm

for

load too cold pump

pump

consumers replace pump replace

load too cold pump

pump

Self-Diagnosis

K Readout in display

replace

piston movement sender

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

electrical system interrupts

rpm

rpm

-----------

engine idling

speed rpm

speed

Test

quantity

load too cold pump

at

quantity (actuation control in quantity rises in time (pump is operated) or constant system memory supply system Final control

pump mixture too

drops

piston movement sender control to control unit position rises in time (pump control closed Observe display block only pump

consumers replace pump replace

load too cold pump

pump

Self-Diagnosis

engine does not

K Readout in display

K Readout in display

piston movement sender

temperature

temperature

replace

consumers up replace

attempt at

replace

pump

not less

pump

pump

pump

up

quantity

piston)

system tester

pump by control unit)

replace

Edition 12.00 S00.5113.53.20

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

control test and set commencement

blocked

control test and set

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

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

commencement valve pump stops too late commencement

too cold

valve pump stops too soon

Self-Diagnosis

commencement o

up

K Readout in display

ratio

up

by control unit

not less

commencement

control test and set commencement

blocked

control test and set

Edition 12.00 S00.5113.53.20 valve

OCTAVIA

OCTAVIA

Notes:

I b S yttV x ah a X V P d XV h I Y V d a Xy VX h ah V beY a V hH h ac x x h b X h h h V Dh ex Q r x h V h h V V r a V X s X V h p VY Xtb h X b h b huh VS aC ht XYX bb ua yu ReV e SP G`Q fV y Vtp X h x a V h X c h S S y y x a a V b VX XC htV Vh Xa b ch P Y e gq V b X wwb yX V dh hVF eae ah x x x VX XY hu Ve X bc h h V b aVgS Vceb aX X XD c ew g acF detY Dh Q td e tb q r v X h V h X b u s XtcD TuF Dgi pYe iG DY Stc `Yw dveC VVuF X XegFE Vcp ah aFh bww VVcV XhgeS hccF bXYw XS VV cheD cX c YYV ee YweD Uw eVc geXF fe Wc RY TC QF PF H Q P I I C E G SF AFeeFe egeegeD ' ( (     6 ! 4 3 '! '9F 'Yce $Xe$F ("Yee@D 8 8' 8 ce s' &euF5 C w %tYF 7 G  )a5 "cct "eFE 2eH5 cc 0F 1VcE #  
Self-Diagnosis or gear

01

at

throttle for

test in

not less than

engine

Accelerate the vehicle at full throttle for the test.

Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read measured value block rpm K Readout in display ratio

commencement valve

valve

control

test and set commencement

commencement commencement up

in display block

too cold

in

valve supply system est pump stops too soon

control supply system leaks test and set commencement

commencement

by control unit

speed

rpm

Edition 12.00 S00.5113.53.20

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

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

01

Notes:

Accelerate the vehicle at full throttle for the test.

Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read measured value block rpm 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

test and set commencement

commencement o commencement up

in display block

too cold

in

valve supply system est pump stops too soon

control supply system leaks test and set commencement

commencement

by control unit

speed

rpm

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

Edition 12.00 S00.5113.53.20

 1     1    B P 1  9  )   E H R Q G D D 6    1 1 1 9 U    4 1  1  (  0  '  1  9   1 5 1 5 9 9 ( S 9 7    7  1   S BI  9$ )R 5      9 9 R 95 9   EI H Q( GFC( D D 1 6 P F I C '  " T 9 B  19 1 1  9) 1   4 2  1  (9 B   36 1  9     1 )    5   ' 9   ' ( &    y v x w 9   1(     1    6    ( (    5)   1 U T S B0f( !8 B$ R 990       9995   )   T    ) (  "   9 U % 9 ' E(  R9 Q(@ D) D 9 6!7 I 2 599   C   6 !!! $  &  1! 1$ 18 ! 9 7!  4 1   1  () 9 1   ( ! ( 07   9  1) (0   ( $  5Y 9 9  f 9 1  )  9 9  9%    9  ( )   5   R  7    1( @ )(   9 S  % B !r B5!  7 (05 (W )9% (       7  9R  ( ( 9  d      9      E Q1 DD D1 ( 6! U C '  8  V I $ 6 % % T(( 98 !0 9!  19 1u 1  f   g 4w!! 1! 20!  @ 1@! (9v 5Y 2 $ 3  1 Y ) 9   &     ) ((      9  ((p 95h    5) 0   $ ! X c ! ! 0 'I    ! ` i   '!s & $ $ % (# (  ) t!! )  #  $ q" a` 95 R b   $ q" y# r!!X fs! Y00 v! x!e f!e v! tq Y ` g f d c b Y w` w! u! a W p i h X )! a ((qa X
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

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

g f e e d e x ge  y   #    $ ey v p $ w gg # # !v#  " u # #e! # # gy !y s # w w # " "$ $ u t e g      g $ s p d c 7 7 Y W 7 5 B C 8 P I P0 SG Qf 7 Ce 9p 6 7 9 &Re ' Ue! T Cy By 9y 7 6 8 @ F A D E C# BV 9# 76 6s 57 87 @p 3i 3# 4q A` D E8 ( 2ea 2 1 & & & & & & & & & 0 & % AXAb #Qh !e) e      $' "    r
Self-Diagnosis

OCTAVIA

ignition

on

Read measured value block

K Readout in display state

pedal monitor

state of cruise control able

brake 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 and brake pedal depressed

pedal depressed

pedal

opened

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

Edition 12.00 S00.5113.53.20

# $ 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

Actuation of heating elements

of

state of

if

less

less

Self-Diagnosis

or

off

able

or

able

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

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

01

c f f e W g W V f f v w t V V d X o c t o g W W W T p c c t s p o f f V W p c T t t T Y T t o s f g p T m l i d g 3 & 2 " T F P DTi c f$ ft I vfW vUo wT vg eW pXd T gp o TV dc Wn td X gt Wf h p S ih y U E h T u vp wUq fp VfXhhUhrh Vd t t Xgrh H r F T Hrh Y f T V s fWI frS fy qh fd t gsXhrh WWdXh Vchh pfG TTh WhW gi WV dfX TT gW WW Vr g W XWI cghU ffXhe fo `a dXr ag eYhXh WW" gi WhG V dk SdI Fd Pg Rt hfj Ip GF GW GUUr G G Tfh SWa YfG FFG FthU P# RY WV VW Tg Xhhn U Sh IhUh F SXn H Qjhe PF PUF RXn F D# 0 $G 3G 2G 2 5!d" 3p7UU% 51 "h3x! 'f 2" 4# "F 2E 3f 2t & &% "W %F 6Xh %F % ' & 9WhGGGG! 7F 7Q 7X$ BF (XTE 8"d0 @i ATy C7T3 ) ( (      Gh G  !  G
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

pedal position sender incorrectly set or and

Self-Diagnosis

K Readout in display

state

temperature

able

up

not less

state

set Repair

Edition 12.00 S00.5113.53.20

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

Edition 12.00 S00.5113.53.20

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

not less than

Read measured value block rpm

K Readout in display ratio

recirculation valve

speed rpm

readout

readout

for

sensors

engine on

not

and

Read measured value block

K Readout in display temperature open circuit in a substitute value

coolant temperature sender temperature is s is

as

temperature open circuit in

readout

temperature intake open circuit in a constant

temperature sender as a substitute value

temperature sender a constant is

as a substitute value

It is not possible to state specifications for the temperatures.

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

Edition 12.00 S00.5113.53.20

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

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

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).

Accelerate the vehicle at full throttle for the test.

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

at

speed

Accelerator pedal not test or

rpm

test in 2nd

Self-Diagnosis

K Readout in display

detected air mass

control on

Repair

Repair

speed too or too increased as a result

accelerator pedal position sender

pedal

and

limit on

basis

recirculation

basis

speed

est air mass meter and

detected air mass

Repair

not less

test and

incorrectly set

Edition 12.00 S00.5113.53.20

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

throttle road test in 2nd or

gear

not less than

for

Accelerate the vehicle at full throttle for the test.

Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read measured value block rpm K Readout in display

limit on

basis

detected air mass

detected air mass Repair

est air mass meter and test and

recirculation

control on

Repair

basis

speed

speed too or too increased as a result pedal

Accelerator pedal not test rpm

accelerator pedal position sender and

incorrectly set or

speed

Repair

Edition 12.00 S00.5113.53.20

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

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

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).

Accelerate the vehicle at full throttle for the test.

Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).

Accelerate the vehicle at full throttle for the test.

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

010 at

010 at

mbar

mbar

test in 2nd

test in 2nd

Self-Diagnosis

mbar

edal

edal

mbar

not less

not less

Edition 12.00 S00.5113.53.20 or or

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

Accelerate the vehicle at full throttle for the test.

Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read measured value block rpm K Readout in display ratio o.k.

valve positioner

speed

readout

readout

rpm o.k.

Edition 12.00 S00.5113.53.20

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

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

OCTAVIA

Fuel Preparation/Fuel Injection

23

Servicing diesel direct injection system


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

Rules for cleanliness


Pay careful attention to the following 5 rules for cleanliness when carrying out work on the fuel supply/fuel injection system: Thoroughly clean connection points and the surrounding area before disconnecting. Place removed parts down on a clean surface and cover over. Do not use fluffing cloths! Carefully cover over or seal opened components if repairs are not carried out immediately. Install only clean parts: Do not remove parts from their wrapping until just before installing. Do not use parts which have been stored unwrapped (e.g. in tool boxes etc.). If the system is opened: Avoid working with compressed air, if possible. Avoid moving the vehicle, if possible. In addition, ensure that no diesel fuel gets onto the coolant hoses. If this happens, it is then necessary to clean the hoses again immediately. Replace any hoses which have suffered damage.

Edition 09.97 S00.5113.51.20

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

23 Survey of fitting locations

Fuel Preparation/Fuel Injection

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)

------------ 23-2 ------------

Edition 09.97 S00.5113.51.20

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

1 - Glow plug relay (J52)

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)

Edition 07.99 S00.5113.52.20

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

23

Fuel Formation/Fuel Injection

OCTAVIA

Removing and installing air filter and throttle valve positioner

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

------------ 23-4 ------------

Edition 07.99 S00.5113.52.20

OCTAVIA

Fuel Preparation/Fuel Injection

23

Removing and installing intake manifold


Removing KDetach the hose pipe from the throttle valve positioner. Slacken the bolt -1- and take off the intake manifold -2-. Take off the shaped rubber element of the cylinder head breather.

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.

Edition 09.97 S00.5113.51.20

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


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

23

Fuel Formation/Fuel Injection

OCTAVIA

Removing and installing injection pump


Special tools, testers and aids required Setting straightedge MP 1-312 Setting device for TDC MP 1-313 Locking pin 3359 Counterholder MP 1-216 Wrench for tensioning toothed belt (e.g. Matra V159, Hazet 2587 or Stahlwille 127-17) Connection fitting V.A.G 1318/10 Vacuum pump, e.g. V.A.G 1390 Torque wrench 5...50 Nm, e.g. V.A.G 1331 Ring wrench for injection lines, e.g. 3035 Puller T40001 with hook T40001/2 and T40001/3 Feeler gauges Steel straightedge (marking tool), if required Transparent plastic line Removing Remove top engine trim panel. Remove all fuel lines of injection pump.

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

------------ 23-6 -----------23-10 ------------

Edition 12.00 S00.5113.53.20

OCTAVIA

Fuel Formation/Fuel Injection

K-

K-

K-

Edition 07.99 S00.5113.52.20

&      # $ ' ( ' %        !     "        


23
installed Take off orifice plate at inspection opening. Position the crankshaft to TDC of cylinder 1 -arrow-. Screw in setting device for TDC MP 1-313, as shown in the illustration. Position setting device to 90 mm -arrow- (the left notch of the vernier -arrow A- is the reference point). Rotate crankshaft until TDC marking -arrow B- on the flywheel is aligned with the edge of the setting device. Position flexible steel ruler (marking tool) around the circumference of the flywheel. Measure exactly 100 mm from the TDC marking -arrow A- and make an aid marking -arrow B- with the marking tool.
-----------------------

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

23

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

Fuel Formation/Fuel Injection

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.

Edition 07.99 S00.5113.52.20

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

Edition 07.99 S00.5113.52.20

Fuel Formation/Fuel Injection

K-

K-

23

23

Fuel Formation/Fuel Injection

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.

------------ 23-12 -----------23-10

Edition 12.00 S00.5113.53.20

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 /
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OCTAVIA

Edition 07.99 S00.5113.52.20

Fuel Formation/Fuel Injection

K Ensure the retaining claw is correctly located.

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 
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23

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Fuel Formation/Fuel Injection

K-

Notes:

and of commencement of injection

The

and

he

Edition 07.99 S00.5113.52.20

OCTAVIA

OCTAVIA

Fuel Formation/Fuel Injection

Test procedure -

Initiate basic setting 1 2 3 4

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.

Edition 12.00 S00.5113.53.20


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

Fuel Formation/Fuel Injection

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

Fuel Formation/Fuel Injection

Read measured value block 15.4 C

15.9 C

7 16.7 C

K-

K-

Edition 12.00 S00.5113.53.20

8 % 0 $ % & 1 % 4 7 5 13 ( 1 0 % 0 1 $ ( & % 1 % 4 5 # ' "   3  ! !  ) 4  2)    '  !    


23
If the commencement of injection is not within the specified range: Correct the setting at the injection pump gear. If the commencement of injection cannot be set within the specified range: Test ejection pressure of pump. 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 23 If the injection pump is in proper order: Replace engine control unit. 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 23 t t and required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Hand-held multimeter (e.g. V.A.G 1526) Test box V.A.G 1598/22 or V.A.G 1598/31 Connect vehicle system tester V.A.G 1552 and select engine electronics control unit page 01-2. (address word 01) Check readout in display block 3. Note: If there is an open circuit in the wiring to the sender, a substitute value of 136.8 C is displayed. If the readout is implausible, or if a temperature of 136.8 C is displayed as a substitute: Unplug connector from the intake manifold pressure sender (G72). Connect multimeter to contacts 1 and 2 of the intake manifold temperature sender for resistance measurement.
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23

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 $ % #        &    !    &       $ % #     ! "  "    !      "  "    !


Fuel Formation/Fuel Injection

OCTAVIA

Specification:

Specification in field A applies to temperatures of 0...50 C, in field B for temperatures of 50...100 C. Example:

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

A temperature of 80 C equals the specification 275...375 If the specification is not achieved: -

Replace intake manifold temperature sender (G72).

If the specification is achieved: -

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

Rectify any open circuit or short circuit in the wiring.

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

Rectify any open circuit or short circuit in the wiring.

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Edition 12.00 S00.5113.53.20

 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
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OCTAVIA

Edition 12.00 S00.5113.53.20

Fuel Formation/Fuel Injection

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

Rectify any open circuit or short circuit in the wiring.

For t

Test the following cable connections for short circuit to positive and to negative and for open circuit. .

2 3

81 75

Rectify any open circuit or short circuit in the wiring.

If no fault is found in the wiring: -

Replace throttle valve positioner -V60.

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Edition 12.00 S00.5113.53.20

OCTAVIA

System in basic setting 900 rpm

Edition 12.00 S00.5113.53.20

F  H   D G F EC C   A C  A  C A A DA  D 9 6 5 1 8 1 8 5 4 0 1 0 2 7 ) ' (     & # 2 % "B3 C %@ " !     $ 


Fuel Formation/Fuel Injection

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 -

Specification in display block 4: 0...5 %

EGR active -

Specification in display block 4: 95...100 %

If the specification is not achieved: -

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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