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Octavia 1997
1.6 l/75 kW Engine, Fuel Injection and Ignition System
List of Supplements to Workshop Manual
Octavia 1997
Edition 06.01
Supplement 1 2
Edition 06.01 08.02 10.04
Subject Basic Edition Changes for engine BFQ Modifications in Rep. Gr. 01 24 and 28
Article Number S00.5135.50.20 S00.5135.51.20 S00.5135.52.20
Edition 10.04 S00.5135.52.20
List of Supplements
Octavia 1997
List of Supplements
Edition 10.04 S00.5135.52.20
Octavia 1997
Table of Contents
01 Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 - Operation ............................................................................................... 01-1 - Technical data of self-diagnosis ..................................................................... 01-1 - Connecting up the vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics ..................................................................................... 01-1 - Interrogating and erasing fault memory ............................................................ 01-1 - Performing actuator diagnosis ....................................................................... 01-1 Self-diagnosis II ......................................................................................... 01-2 - Fault codes 16486 16990 ......................................................................... 01-2 Self-diagnosis III ........................................................................................ 01-3 - Fault codes 17040 18088 ......................................................................... 01-3 Self-diagnosis IV ....................................................................................... 01-4 - Readiness code ........................................................................................ 01-4 - Reading readiness code .............................................................................. 01-4 - Generating readiness code .......................................................................... 01-4 Self-diagnosis V ........................................................................................ 01-5 - Reading measured value block ..................................................................... 01-5 - Display groups 001 up to 028 ....................................................................... 01-5 Self-diagnosis VI ....................................................................................... 01-6 - Reading measured value block - display groups 030 to 132 ................................... 01-6 page page page page page page page page page page page page page page page page page page page 1 1 1 2 3 4 1 1 1 1 1 1 1 2 1 1 1 1 1
24 Fuel Formation, Injection

Fuel Injection System ................................................................................. 24-1 - Safety measures ....................................................................................... 24-1 - Rules of cleanliness ................................................................................... 24-1 - Overview of fitting locations .......................................................................... 24-1 - General notes on the injection system ............................................................. 24-1 - Removing and installing parts of the injection system ........................................... 24-1 - Disassembling and assembling fuel distributor with injectors .................................. 24-1 - Disassembling and assembling top part of intake manifold ..................................... 24-1 - Disassembling and assembling the air filter ....................................................... 24-1 - Resistances for intake air temperature sender -G42- ........................................... 24-1 - Resistances for the coolant temperature sender -G62- ......................................... 24-1 Testing components ................................................................................... 24-2 - Test wiring and components with Test box -V.A.G 1598/31- ................................... 24-2 - Inspecting the injection rate, tightness and jet formation of the injectors ..................... 24-2 - Test fuel pressure regulator and holding pressure ............................................... 24-2 - Testing the intake system for tightness (unmetered air) ........................................ 24-2 - Testing brake vacuum pump -V192- ............................................................... 24-2 Inspecting functions ................................................................................... 24-3 - Testing idling speed ................................................................................... 24-3 - Testing the intake manifold changeover ........................................................... 24-3 Lambda control ......................................................................................... 24-4 - Testing lambda probe -G39- and lambda control upstream of catalytic converter .......... 24-4 page page page page page page page page page page page page page page page page page page page page page 1 1 1 2 4 5 7 8 9 9 1 1 2 4 5 6 1 1 2 1 1
page 10
Edition 10.04 S00.5135.52.20
Table of Contents
Octavia 1997
1.6 l/75 kW Engine, Fuel Injection and Ignition System page page page page page page page page page page page page page page page page page page 2 3 1 1 1 3 1 1 1 2 4 6 6 7 1 1 2 3
- Testing lambda probe -G130- and lambda control downstream of catalytic converter ..... 24-4 - Test of ageing of lambda probe upstream of catalytic converter -G39- ....................... 24-4 Electronic Engine Power Control (Electronic throttle) ........................................ 24-5 - Inspecting fault lamp for the EPC ................................................................... 24-5 - Testing throttle valve control unit -J338- ........................................................... 24-5 - Testing Accelerator pedal position sender ........................................................ 24-5 Engine control unit .................................................................................... 24-6 - Operation ............................................................................................... 24-6 - Replacing engine control unit ........................................................................ 24-6 - Coding engine control unit ........................................................................... 24-6 - Adapting the 4AV control unit to the throttle valve control unit -J338- ........................ 24-6 - Adapting EGR valve .................................................................................. 24-6 - Activating and deactivating cruise control system (CCS) ....................................... 24-6 - Learning kickdown operating point ................................................................. 24-6 Testing auxiliary signals ............................................................................. 24-7 - Testing signal from high pressure sender for the air conditioning system -G65- ............ 24-7 - Testing the speed signal ............................................................................. 24-7 - Checking the data BUS .............................................................................. 24-7
28 Ignition System
Ignition System ......................................................................................... 28-1 - General notes on the ignition system .............................................................. 28-1 - Safety measures ...................................................................................... 28-1 - Removing and installing ignition system ........................................................... 28-1 - Inspecting the camshaft position sensor -G163- ................................................. 28-1 page page page page page 1 1 1 2 3
II
Table of Contents
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Octavia 1997
01
01-2
Self-diagnosis II
Fault codes 16486 16990

Note
The fault table is arranged according to the 5-digit fault code on the left. The SAE code which is displayed on the right next to the fault code (e.g.. P0107) can be ignored (at present only
valid for USA).

Explanations regarding fault types (e.g. open circuit or short-circuit to earth) Operating instructions for the ve-
hicle system tester.

If parts are output as faulty: First check all cables and connectors to these components as well as the earth con-
nections according to the Current Flow Diagram. Only if no fault is detected here should the part be replaced. This applies in particular if faults are shown as sporadic (SP).
If literature appears in the display of the vehicle system tester -V.A.G 1552- look for the text required in the fault
table under the fault code.

Readout on -V.A.G 155216486 Air mass meter -G70 16487 Air mass meter -G70 Signal too low Signal too high Rectifying fault
Read measured value block, display group 002, display

field 4 Chap. 01-5. flow diagram.
Test wiring and plug connections according to current Testing intake system for leaks (unmetered air)
Chap. 24-2.
Replace air filter if necessary Chap. 24-1.

16496 Signal too low Intake air temperature sender G42 16497 Signal too high Intake air temperature sender G42 16500 Coolant temperature sender G62 16501 Coolant temperature sender G62 16502 Coolant temperature sender G62 16514 Bank 1, probe 1 16515 Bank 1, probe 1 16516 Bank 1, probe 1 16517 Bank 1, probe 1 16518 Bank 1, probe 1 16520 Bank 1, probe 2 Implausible signal

field 4 Chap. 01-5.
Test resistances Chapter 24-1. Test wiring and plug connections according to current
flow diagram.

Signal too low field 3 Chap. 01-5.
Signal too high
Test resistances Chapter 24-1. Test wiring and plug connections according to current
flow diagram.
Electrical fault in the circuit Voltage too low Voltage too high Signal too slow No activity Electrical fault in the circuit
Test lambda probe -G39- and lambda control upstream

of catalytic converter Chapter 24-4.
Test lambda probe -G130- and lambda control downstream of catalytic converter Chapter 24-4
Edition 10.04 S00.5135.52.20
Self-diagnosis II
01-2 page 1
01
Readout on -V.A.G 155216521 Bank 1, probe 2 16522 Bank 1, probe 2 16524 Bank 1, probe 2 16554 Bank 1, fuel metering system
Octavia 1997
1.6 l/75 kW Engine, Fuel Injection and Ignition System Rectifying fault
Voltage too low Voltage too high No activity Malfunction
Test lambda probe -G130- and lambda control downstream of catalytic converter Chapter 24-4.
Test fuel pressure regulator and holding pressure

Chap. 24-2
Test injection valves Chapter 24-2 Test fuel pump 1.6/75 Engine, Mechanical Components; Rep. Gr. 20
Inspect exhaust system for leaks 1.6/75 kW Engine,

Mechanical Components; Rep. Gr. 26
Inspect secondary air system for leaks 1.6/75 kW

Engine, Mechanical Components; Rep. Gr. 26
Inspect vacuum lines for leaks Testing intake system for leaks (unmetered air)
Chap. 24-2. 16555 Bank 1, fuel metering system 16556 Bank 1, fuel metering system 16684 Combustion misfiring detected 16685 Cyl. 1 Combustion misfiring detected 16686 Cyl. 2 Combustion misfiring detected 16687 Cyl. 3 Combustion misfiring detected 16688 Cyl. 4 Combustion misfiring detected 16705 Engine speed sender -G28 16706 Engine speed sender -G28 16711 Knock sensor 1 -G61 16712 Knock sensor 1 -G61 Implausible signal No signal System too lean System too rich
Test lambda probe -G39- and lambda control upstream

of catalytic converter Chapter 24-4.

Chap. 24-2
Check the resistance values of the injectors (12...17

at approx. 20 C).
Test ignition cables and spark plugs Chap. 28-1. Test power output stage -N122- Chapter 28-1. Read measured value block, display groups 014, 015
and 016 Chap. 01-5.
Test resistance of sender (7301000 ). Test wiring and plug connections according to current
flow diagram.
Replace engine speed sender -G28-.

Signal too low
Read measured value block, display groups 020, 026

Signal too high and 028 Chap. 01-5.
01-2 page 2
Self-diagnosis II
Edition 10.04 S00.5135.52.20
Octavia 1997
1.6 l/75 kW Engine, Fuel Injection and Ignition System Rectifying fault Malfunction
01
Readout on -V.A.G 155216719 Engine speed sender -G28
Test resistance of sender (7301000 ). Test wiring and plug connections according to current
flow diagram.
Replace engine speed sender -G28-.

16725 Camshaft pos. sensor => Sender G40 1) 16726 Camshaft pos. sensor => Sender G40 1)
1)
Implausible signal
Read measured value block; display group 012; check

values in display fields 3 and 4 Chapter 01-5.
Signal too low
Test camshaft position sensor -G163- Chap. 28-1. Test wiring and plug connections according to current
flow diagram.
Camshaft position sensor -G163- and camshaft pos. sensor => Sender -G40-are identical.
Readout on -V.A.G 155216788 EGR system control difference Signal too low
Rectifying fault
Test exhaust gas recirculation valve -N18- with final

control diagnosis Chap. 01-1.
Adapt EGR valve -N18- Chap. 24-6. Test exhaust gas recirculation system 1.6/75 Engine, Mechanical Components; Rep. Gr. 26 Efficiency too low 16804 Bank 1, catalytic converter system
Generate readiness code Chapter 01-4. Inspect exhaust system for leaks or inspect for damage
if necessary between both lambda probes 1.6/75 Engine, Mechanical Components; Rep. Gr. 26.
16825 Tank ventilation system
Flow rate incorrect
Perform emission test Inspection and Maintenance. Test solenoid valve 1 for activated charcoal filter system -N80- with the final control diagnosis Chapter 01-1.
Inspect hoses and connection pipes from fuel tank up Test wiring and plug connections according to current
flow diagram. 16845 Fuel gauge signal Implausible signal
to the throttle valve control unit 1.6/75 Engine - Mechanical Components; Rep. Gr. 20.
Test fuel gauge sender -G- Electrical System;

Rep. Gr. 90.
Test CAN databus Chap. 24-7. Test dash panel insert Electrical System;
Rep. Gr. 90. 16885 Vehicle speed signal Implausible signal
Reading measured value block, display group 005,

checking values in display field 3 Chap. 01-5.
Test vehicle speed signal Chapter 24-7. Test CAN databus Chap. 24-7. Test dash panel insert Electrical System;
Rep. Gr. 90. 16890 Idling control 16891 Idling control Speed under nominal value Speed above nominal value
Test throttle valve control unit -J338- Chapter 24-5. Testing intake system for leaks (unmetered air)
Chap. 24-2.
Adapt throttle valve control unit Chapter 24-6.
Edition 10.04 S00.5135.52.20
Self-diagnosis II
01-2 page 3
01
Readout on -V.A.G 155216916 AC pressure sensor -G65 16917 AC pressure sensor -G65 16935 PAS pressure/switch -F88 16946 Voltage supply
Octavia 1997
1.6 l/75 kW Engine, Fuel Injection and Ignition System Rectifying fault
Signal too low
Test signal from high pressure sensor for air conditionSignal too high Implausible signal Voltage too low ing -G65- Chapter 24-7.
Read measured value block, display group 055, check

readouts in display field 4 Chapter 01-6.
Test voltage supply of engine control unit Current

Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test battery and alternator Electrical System;

Rep. Gr. 27 16955 Brake light switch -F Implausible signal
Read measured value block, display group 066

Chapter 01-6. flow diagram.
Test wiring and plug connections according to current

16984 Databus drive 16985 Control unit defective 16988 Control unit defective 16990 Control unit defective missing message
Test CAN databus Chap. 24-7. Read out fault memory of all control units.
Replace engine control unit Chapter 24-6.
01-2 page 4
Self-diagnosis II
Edition 10.04 S00.5135.52.20

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01
01-4
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Readiness code
Operation
The readiness code is an 8-digit numerical code that provides information on the status of the emission-relevant diagnosis. If the diagnosis for a system was successfully performed (e.g. diagnosis of catalytic converter), the relevant position of the numerical code is set from 1 to 0. This diagnosis is performed at regular intervals during normal driving. If repairs have been done on a system relevant for the exhaust gas it is recommended to generate the readiness code as this guarantees that these systems operate according to the specifications. If a fault is detected during diagnosis, it is then stored in the fault memory. The readiness code is erased if the fault memory is erased or if there is an interruption to the voltage supply.
Reading readiness code

Special tools, test and measuring equipment and auxiliary items required
Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
Connect vehicle system tester -V.A.G 1552-. Switch

ignition on and select address word 01 Engine electronics Chap. 01-1.
Function
with Q .
1 5 enter readiness code and confirm Readiness code 00000000 - Test complete ->
The following readout must appear in the display after successfully completing all the checks:
Press
.
0 6 End output and confirm with Q . Readiness code 00101101 - Test not complete ->
Enter function
Read-out on display: Not all checks were performed successfully.
Press . Generate readiness code 01-4 page 2.
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Meaning of the 8-digit numerical block of the readiness code
X 0
X 0
Checked system Exhaust gas recirculation Lambda probe heater
0 0 0 0 0 0
Lambda probes Air conditioning (no diagnosis at present/always 0) Secondary air system Activated charcoal filter (tank vent system) Catalytic converter heater (no diagnosis at present/always 0) Catalytic converter
Generating readiness code

Test conditions
Vehicle stopped. All electrical components such as lights and rear window heater must be switched off.
On vehicles with an automatic gearbox the selector lever must be in position P or N.
The coolant temperature must be at least 80C

display group 004, display field 3. display group 004, display field 4.
The intake air temperature must be below 60 C
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics Chapter 01-1.
Work step 1: Interrogating fault memory
Enter address word

and confirm with Q .
0 2 Interrogate fault memory X faults detected
The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
Rectify the faults by referring to the fault table

Chapter 01-2 and 01-3. If no fault is stored:
Press
01-4 page 2
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Work step 2: Erasing fault memory
Enter address word

confirm with Q . Note
0 5 Erase fault memory and
The readiness code is reset or erased each time the fault memory is erased.
Readout on display: Note
Vehicle system test The fault memory is erased ->
If the ignition is switched off during Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Press
Work step 3: Diagnosis of secondary air injection system
Select function
0 4 initiate basic setting and conInitiating basic setting Enter display group number XXX
firm entry with Q . Readout on display:
0 7 7 for the indicator group 077 and confirm en-
try with
Q. System in basic setting 77 700 rpm 1.9 g/s 0.0 % -> Test ON
Readout on display: For engines with engine code BFQ
Depress brake pedal and accelerator simultaneously.

For engines with engine code AVU
Depress brake pedal and hold pressed.

Continued for all engines Engine speed is increased and the readout in display field 4 switches from Test OFF to Test ON.
Run engine at high speed until specified value Syst.

O.K. appears If the display does not occur as described:
Interrogate fault memory Chapter 01-1.

If the display occurs as described:
Press
C.
Work step 4: Diagnosis of exhaust gas recirculation system

Readout on display:
Initiating basic setting Enter display group number XXX
try with
Q.
Readout on display:
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System in basic setting 75 700 rpm 18.4 % -2.3 %
-> System O.K.
Self-diagnosis IV
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After initiating diagnosis of engine control unit the display in field 4 changes from Test OFF to Test ON.
Run engine at idling speed until Syst. O.K. is displayed in display field 4. If the display does not occur as described:

Press
C.
Work step 5: Catalyst diagnosis

Readout on display:
try with
Q. System in basic setting 46 700 rpm 250,0 C 0,96 -> Test OFF
Depress brake pedal and accelerator simultaneously. Engine speed is increased and the readout in display
field 4 switches from Test OFF to Test ON. For engines with engine code AVU
Set speed to 2500...4500 rpm. The readout in display

field 4 changes from Test OFF to Test ON. Continued for all engines
Catalytic converter temperature in display field 2 must

be at least 400 C. Note
This may take a few mlnutes.
Maintain the speed until the readout in display field 4

shows the specified value CatB1 O.K.. If the display does not occur as described:

No fault in the fault memory:
Conduct a test drive at a constant speed. Pay attention to safety precautions for test drives
Chapter 24-1.
Once again perform (test of conversion) diagnosis of

catalytic converter. In case of equal result:
Replace catalytic converter 1.6 l/75 kW Engine,

Mechanical Components; Rep. Gr. 26. If the display occurs as described:
Press
C.
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Work step 6: Diagnosis of lambda probe after catalyst (ageing test)
try with
Q. System in basic setting 43 700/min 200.0 C 0.85 V -> Test OFF


Continue running engine at higher speed until the catalytic converter temperature in display field 2 shows at least 200 C. Note
Run engine at high speed until display field 4 indicates

specified value B1-S2 O.K.. If the display does not occur as described:

Press
C.
Work step 7: Diagnosis of lambda probe before catalyst (ageing test)

Readout on display:
try with
Q. System in basic setting 34 700 rpm 300.0 C 0.000 -> Test OFF


Catalytic converter temperature in display field 2 must

be at least 350 C.
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Note
Octavia 1997
Run engine at high speed until display field 4 indicates

specified value B1-S1 O.K.. If the display does not occur as described:

Press
C.
Work step 8: Diagnosis of activated charcoal filter system (tank vent system)
Readout on display:
try with
Q. System in basic setting 70 4.3 % 10.9 % -1.1 % -> Test OFF
Readout on display: After initiating diagnosis of engine control unit the display in field 4 changes from Test OFF to Test ON.
Run engine at idling speed until display field 4 indicates specified value TEV O.K.. If the display does not occur as described:

Press . Read out readiness code 01-4 page 1.
01-4 page 6
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01-5
Self-diagnosis V
Reading measured value block

Test conditions
Coolant temperature must be at least 80 C. All electrical consumers such as e.g. rear window
heater must be switched off.
Procedure
Connect vehicle system tester - V.A.G 1552-. Start

engine and select address word 01 Engine electronics Chapter 01-1. Readout on display:
Vehicle system test Select function XX 0 8 Read measured value Reading measured value block Enter display group number XXX HELP
Enter address word

Readout on display:
block and confirm the entry with key Q .
Select desired display group:
Display groups 001 up to 028 01-5 page 1. Display groups from 030 Chap. 01-6.
Display groups 001 up to 028
Display group 001 - Basic functions setting conditions

Engine idling Coolant temperature 80 C
Reading measured value block 1 xxx rpm 1 xxx.x C 2 xx.x % 3
xxxxxxxx 4
Lambda control before catalyst Coolant temperature Engine speed (idling speed)
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< Readout on display < Display field Setting condition for basic setting
Self-diagnosis V
Specification 1x111111
Analysis 01-5 page 2 01-5 page 2 01-5 page 5 01-5 page 2
-10,010,0 %
80,0115.0 C 640900 /rpm
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Analysis: Display group 001, display field 1 - engine speed (idling speed)
Display -V.A.G 1552less than 640 rpm
Possible cause of fault

Throttle valve control unit jams/defective
Rectifying fault
Test throttle valve control unit Chapter

24-5.
inspecting idling speed Chapter 24-3.

greater than 900 rpm
Idling not detected Large quantity of unmetered air between
intake manifold and air mass meter

Throttle valve control unit jams/defective
Interrogate fault memory Chapter 01-1. Inspecting air intake system for tightness
(unmetered air) Chapter 24-2.

24-5.
inspecting idling speed Chapter 24-3.
Analysis: Display group 001, display field 3 - lambda control before the catalytic converter
Display -V.A.G 1552 -
Rectifying fault
not within tolerance Minimum range: Mixture too rich, the lambda control leans the mixture Plus range: Mixture too lean, lambda control enriches Unmetered air Injection valve defective
wait 30 seconds until the display has stabilised
Testing intake system for tightness

Chap. 24-2.
Check the resistance values of the injectors (12...17 at approx. 20 C).
Test wiring and plug connections according to current flow diagram.
Analysis: Display group 001, display field 4 - Setting conditions for basic setting
X 1
X x
Meaning No fault detected by the self-diagnostic function Disregard display
1 1 1 1 1 1
AC compressor disconnected Idling detected Lambda control: o.k. Throttle valve closed Engine speed less than 2000 rpm Coolant temperature more than 80C
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Display group 002 Basic functions injection time, air mass meter
Engine idling Coolant temperature 80 C x.x g/s 4 < Display field Drawn in air mass Injection period Engine load Engine speed (idling speed) Specification 2,04.5 g/s 2,04.0 ms 15,035,0 % 640900 /rpm Analysis 01-5 page 3 01-5 page 3 01-5 page 7 01-5 page 2 < Readout on display
Reading measured value block 2 xxx rpm 1 xxx.x % 2 x.x ms 3
Analysis: Display group 002, display field 3 - injection time
Display -V.A.G 1552 less than 2.0 ms

high fuel volume from the activated char-
Rectifying fault
Test solenoid valve 1 for activated charcoal filter system -N80- with the final control diagnosis Chapter 01-1.
coal filter system

incorrect injection valve with too great
flow rate fitted greater than 4.0 ms increased engine load due to electrical consumers (air conditioning system, fog lights etc.)
Test injected quantity Chapter 24-2. Eliminate increased load (AC, fog lights
etc.).
Analysis: Display group 002, display field 4 - inducted air mass
Display -V.A.G 1552 less than 2.0 g/s

Large quantity of unmetered air between
Rectifying fault
intake manifold and air mass meter greater than 4.5 g/s Gear engaged (automatic gearbox)
Engine loaded by auxiliary equipment
Eliminate unmetered air. Move selector lever into position P or

N.
Eliminate load (AC, power steering etc.).
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Display group 003 Basic functions air mass meter, throttle valve angle
Engine idling Coolant temperature 80 C xx.x b. TDC 4 < Display field Ignition angle Throttle valve angle Drawn in air mass Engine speed (idling speed) Specification 0,015.0 b. TDC 1,54,0 % 2,04.5 g/s 640900 /rpm Analysis -- 01-5 page 4 01-5 page 3 01-5 page 2 < Readout on display
Reading measured value block 3 xxx rpm 1 x.xx g/s 2 x.x % 3
Analysis: Display group 003, display field 3 - throttle valve angle
Display -V.A.G 1552 greater than 4.0 %

Engine control unit not adapted to throttle
Rectifying fault
Adapt engine control unit to throttle valve

control unit Chapter 24-6.
valve control unit

Throttle valve potentiometer in throttle

24-5.
valve control unit faulty

Throttle valve jams
Remove fault.
Display group 004 Basic functions temperature

Engine idling Coolant temperature 80 C xxx.x C 4 < Display field Intake manifold temperature Coolant temperature Supply voltage of the engine control unit Engine speed (idling speed) Specification -38,080,0 C 80,0115.0 C 12,514,5 V 640900 /rpm Analysis 01-5 page 5 01-5 page 5 01-5 page 5 01-5 page 2 < Readout on display
Reading measured value block 4 xxx rpm 1 xx.x V 2 xxx.x C 3
01-5 page 4
Self-diagnosis V
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Analysis: Display group 004, display field 2 - supply voltage to the engine control unit
Display -V.A.G 1552 less than 12.5 V

AC generator defective, battery heavily
Rectifying fault
Test alternator and battery voltage

Electrical System; Rep. Gr. 27.
discharged
Battery heavily loaded just after start by a
Increase engine speed slightly for a few

minutes and switch off additional consumers.
high charge current or by auxiliary equipment

Transition resistance in the power supply
Check the supply voltage of the engine
or earth connection for engine control unit
control unit Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Current consumption with ignition off
Rectify any current drain. Test voltage regulator, replace if necessary Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
greater than 14.5 V Voltage regulator on generator defective
Overvoltage due to starting aid or quick
charger
Analysis: Display group 004, display field 3 - coolant temperature
Display -V.A.G 1552 less than 80,0 C

Engine too cold
Rectifying fault
Conduct road test if necessary. Coolant temperature sender or cable con- Test resistances Chapter 24-1.
nection to engine control unit faulty
greater than 115,0 C
Radiator dirty Radiator fan not operational Thermostat for map-controlled engine
Clean radiator. Perform actuator diagnosis Chapter 011.
Test thermostat for map-controlled engine Test resistances Chapter 24-1. Test wiring and plug connections according to current flow diagram.
cooling system faulty

Coolant temperature sender or cable con-
cooling system 1.6l/75 kW Engine, Mechanical Components; Rep. Gr. 19.
nection to engine control unit faulty
constant 30,0 or 49,5 C
Line interruption or short-circuit
Test wiring and plug connections to coolant temperature sender -G62- according to current flow diagram.
Analysis: Display group 004, display field 4 - intake air temperature
Display -V.A.G 1552 constant 9.0 or 30.0 C

Line interruption, short-circuit to positive
Rectifying fault
or earth
Test resistances Chapter 24-1. Test wiring and plug connections to intake
air temperature sender -G42- according to current flow diagram.
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Display group 005 Engine operating state

Engine idling Coolant temperature 80 C Text 4 < Display field Operating condition (idling, partial load, enrichment, trailing throttle, full load) Driving speed Engine load Engine speed (idling speed) Specification Idling Analysis --< Readout on display
Reading measured value block 5 xxx rpm 1 xxx.x % 2 xxx km/h 3
0 km/h 15,035,0 % 640900 /rpm
-- 01-5 page 7 01-5 page 2
Display group 006 Basic functions altitude correction factor

Engine idling Coolant temperature 80 C xx.x % 4 < Display field Level correction factor Intake manifold temperature Engine load Engine speed (idling speed) Note on display field 3: The overall temperature range is indicated as nominal value. The display value must be higher than the ambient temperature. Note on display field 4: Altitude NN 1000 m 2000 m Readout +5-10 -5-20 -10-30 Specification -50,010,0 % -38,080,0 C 15,035,0 % 640900 /rpm Analysis -- 01-5 page 5 01-5 page 7 01-5 page 2 < Readout on display
Reading measured value block 6 xxx rpm 1 xxx % 2 xxx.x C 3
01-5 page 6
Self-diagnosis V
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Display group 010 Ignition angle

Engine idling Coolant temperature 80 C xx.x b. TDC 4 < Display field Ignition angle Throttle valve angle (potentiometer 1 -G187-) Engine load Engine speed (idling speed) Note on display field 3: When accelerator fully depressed, the readout must be approx. 100 %. Specification 0,015.0 b. TDC 1,54,0 % 15,035,0 % 640900 /rpm Analysis -- 01-5 page 7 01-5 page 7 01-5 page 2 < Readout on display
Reading measured value block 10 xxx rpm 1 xxx % 2 x.x % 3
Analysis: Display group 010, display field 2 - engine load
Display -V.A.G 1552 less than 15.0 %

lower value can only occur during trailing
Rectifying fault
throttle driving
Unmetered air

Chap. 24-2.
greater than 35,0 %
Poor idling (engine not running on all cyl-
Injector or spark plugs faulty. Switch off electrical consumers. Turn steering wheel into middle position. Move selector lever into position P or
N.
inders)
Electrical consumers on Steering wheel at limit stop Gear engaged (automatic gearbox) Air mass meter faulty
Test wiring and plug connections to air

mass meter -G70- according to current flow diagram.
Analysis: Display group 010, display field 3 - throttle valve angle
Display -V.A.G 1552 greater than 4.0 %

Engine control unit not adapted to throttle
Rectifying fault
Adapt engine control unit to throttle valve

control unit Chapter 24-6. 24-5.
valve control unit

Throttle valve potentiometer in throttle
Test throttle valve control unit Chapter Remove fault.
valve control unit faulty

Throttle valve jams
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01
Display group 011 Ignition angle
Engine idling Coolant temperature 80 C xx.x b. TDC 4
Octavia 1997
Reading measured value block 11 xxx rpm 1 xxx.x C 2 xxx.x C 3
< Readout on display
< Display field Ignition angle
Specification 0,015.0 b. TDC -38,080,0 C 80,0115.0 C 640900 /rpm
Analysis ---- 01-5 page 5 01-5 page 2
Intake manifold temperature Coolant temperature Engine speed (idling speed)
Display group 012 Position of camshaft relative to crankshaft

Engine idling Coolant temperature Reading measured value block 12 xxx rpm 1 xxx.x % 2 xx 3 80 C xx 4 < Display field No. of crankshaft tooth at change of camshaft slope from high - low No. of crankshaft tooth at change of camshaft slope from low - high Engine load Engine speed (idling speed) Specification 8690 Analysis --< Readout on display
2630
---
15,035,0 % 640900 /rpm
01-5 page 7 01-5 page 2
Display group 014 Ignition misfiring recognition

Driving Coolant temperature 80 C Text 4 < Display field Misfiring detection (activated, deactivated) Sum of ignition misfiring Engine load Engine speed (idling speed) Specification activated x 0,0100,0 % 6406500 /rpm Analysis -- 01-5 page 10 ----< Readout on display
Reading measured value block 14 xxxx rpm 1 xxx % 2 xxx 3
01-5 page 8
Self-diagnosis V
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Note on display field 3: What is stated is not the specification as the misfiring rate is checked continuously in the engine control unit. If the fault threshold is exceeded, the fault entries are made and the exhaust warning lamp flashes or lights up.
Display group 015 Ignition misfiring recognition cylinders 1 to 3

Driving Coolant temperature 80 C Text 4 < Display field Misfiring detection (activated, deactivated) Ignition misfiring cyl. 3 Ignition misfiring cyl. 2 Ignition misfiring cyl. 1 Note on display fields 1 to 3: What is stated is not the specification as the misfiring rate is checked continuously in the engine control unit. If the fault threshold is exceeded, the fault entries are made and the exhaust warning lamp flashes or lights up. Specification activated x x x Analysis -- 01-5 page 10 01-5 page 10 01-5 page 10 < Readout on display
Reading measured value block 15 xxxx 1 xxx 2 xxx 3
Display group 016 Ignition misfiring recognition cylinder 4

Driving Coolant temperature 80 C Text 4 < Display field Misfiring detection (activated, deactivated) no display no display Ignition misfiring cyl. 4 Note on display field 1: What is stated is not the specification as the misfiring rate is checked continuously in the engine control unit. If the fault threshold is exceeded, the fault entries are made and the exhaust warning lamp flashes or lights up. x Specification activated Analysis ------ 01-5 page 10 < Readout on display
Reading measured value block 16 xxxx 1 xxx 2 xxx 3
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Analysis: Display group 014, 015 and 016 - ignition misfiring
Display -V.A.G 1552 -
Rectifying fault
counts up continu- Spark plug defective ously possible mis- Spark plug connector defective firing fault code in Power output stage -N122- faulty fault memory
Injection valve defective
Test spark plugs and spark cables with

spark plug connector Chap. 28-1. Chapter 28-1.
Test power output stage -N122 Check the resistance values of the injector
(12...17 at approx. 20 C).
Test wiring and plug connections to injectors according to current flow diagram. Chap. 24-2.
Unmetered air
Exhaust gas recirculation valve jams
Display group 020 Ignition angle retardation

Driving Coolant temperature 80 C
Reading measured value block 20 xx.x BTDC 1 xx.x BTDC 2 xx.x BTDC 3
xx.x BTDC 4
Ignition angle relief cylinder 3 through knock control
Ignition angle relief cylinder 2 through knock control Ignition angle relief cylinder 1 through knock control
01-5 page 10
< Readout on display < Display field Specification Ignition angle relief cylinder 4 through knock control
Self-diagnosis V
Testing intake system for tightness Test exhaust gas recirculation valve -N18with final control diagnosis Chap. 01-1.
Analysis 01-5 page 11
0,015.0 b. TDC
0,015.0 b. TDC
01-5 page 11 01-5 page 11 01-5 page 11
0,015.0 b. TDC
0,015.0 b. TDC
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Display group 023 Knock control

Driving Coolant temperature 80 C xx.x BTDC 4 < Display field Ignition angle relief cylinder 4 through knock control Ignition angle relief cylinder 3 through knock control Engine load Engine speed Specification 0,015.0 b. TDC Analysis 01-5 page 11 < Readout on display
Reading measured value block 23 xxxx rpm 1 xxx.x % 2 xx.x BTDC 3
0,015.0 b. TDC 0,0100,0 % 6406500 /rpm
01-5 page 11 -----
Analysis: Display group 020 and 023 - ignition angle retardation
Display -V.A.G 1552 all cylinders great than 15 BTDC

Knock sensor defective Plug connection at knock sensor corrod-
Rectifying fault
Test wiring and plug connections to knock

sensor -G61- according to current flow diagram.
ed
Knock sensor incorrectly tightened Component parts on engine loose poor fuel quality
Slacken knock sensor and tighten again to

20 Nm.
one cylinder clearly deviates from the others
Plug connection at knock sensor -G61-
Tighten loosened attached parts. Change grade of fuel. Test wiring and plug connections to knock
sensor -G61- according to current flow diagram.
corroded
Engine damage
Testing compression pressure 1.6 l/75

kW Engine, Mechanical Components; Rep. Gr. 15
Component parts on engine loose
Tighten loosened attached parts.
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Display group 026 Knock sensor voltage signal

Engine idling Coolant temperature 80 C x.xxx V 4 < Display field Knock sensor voltage signal cyl. 4 Knock sensor voltage signal cyl. 3 Knock sensor voltage signal cyl. 2 Knock sensor voltage signal cyl. 1 Specification 0,2002 000 V 0,2002,000 V 0,2002,000 V 0,2002,000 V Analysis --------< Readout on display
Reading measured value block 26 x.xxx V 1 x.xxx V 2 x.xxx V 3
Display group 028 Knock control

Mode basic setting 04 Driving Coolant temperature 80 C Text 4 < Display field Result knock control (Test ON, Test OFF, Syst. O.K., Syst. N.O.K.) Coolant temperature Engine load Engine speed Specification Syst. o.k. Analysis --< Readout on display
Reading measured value block 28 xxx rpm 1 xxx.x % 2 xxx.x C 3
80,0115.0 C 40100 % 6406500 /rpm
01-5 page 5 -----
01-5 page 12
Self-diagnosis V
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01-6
Self-diagnosis VI
Reading measured value block - display groups 030 to 132

Display group 030 Lambda control
Reading measured value block 30 xxx 1 xxx 2 3
no display
Status lambda control downstream of catalytic converter Status lambda control upstream of catalytic converter
Note
The first position in the 3-digit numerical block fluctuates initially between 0 and 1 (lambda probe heater OFF and ON).
Note
regarding display field 2
The third position of the display number changes to 1
under load.
Analysis: Display group 030, display field 1 and 2 - status of lambda control
X 1 1 1 X X Meaning
Lambda probe heater
Lambda probe operational Lambda control active
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< Readout on display 4 < Display field no display 110 111

Self-diagnosis VI
01
Specification
01-6 page 1
01
Display group 031, lambda control - lambda values upstream of catalytic converter
Reading measured value block 31 x.xxxx 1 x.xxxx 2 3
no display
Lambda nominal value - Bank 1 Lambda actual value - Bank 1
Display group 032, lambda control - lambda learned values

Reading measured value block 32 xx.x % 1 xx.x % 2 3
no display
Lambda learned value at part load (multiplicative) Lambda learned value at idling speed (additive)
Note
to the display fields 1 and 2:
Low readouts indicate that the engine is running too rich and the lambda control therefore produces a leaner mix-
ture.
High readouts mean that the engine is running too lean and the lambda control therefore produces a richer mixture. add = additive - The effect of the fault (e.g. unmetered air) becomes increasingly less as engine speed rises. In the
case of an additive initialisation value the injection period is changed by a fixed rate. This rate is independent of the basic injection period.
mul = multiplicative - The effect of the fault (e.g. faulty injector) becomes greater as engine speed rises. The mul-
tiplicative learned value is a percentage change in the injection period. This change is dependent on the basic injection period.
01-6 page 2

Octavia 1997 < Readout on display 4 < Display field no display < Readout on display 4 < Display field no display
Self-diagnosis VI
Specification
Analysis ---------
0,99001,0100 0,99001,0100
Specification
-10,010,0 % -14,014,0 %
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01
Analysis: Display group 032, display field 1 and 2 Lambda learned values
Display -V.A.G 1552 low lambda learned values

Low learned values when idling at normal
Rectifying fault
Disappears after driving on motorway or

changing oil.
learned values under partial load: Oil dilution (higher fuel content in the oil) possible
Injection valve leaks Fuel pressure too high Solenoid valve 1 for activated charcoal fil-
Test for lack of leaks and spray pattern of

injectors Chapter 24-2
Test fuel pressure regulator and holding

pressure Chap. 24-2.
Test solenoid valve 1 for activated charcoal filter system with the final control diagnosis Chapter 01-1.
ter constantly open

Air mass meter faulty
Test wiring and plug connections to air

mass meter -G70- according to current flow diagram.
Lambda probe heater faulty or lambda
Test lambda probe -G39- and lambda control upstream of catalytic converter Chapter 24-4.
probe -G39- dirty high lambda initiali- High learned values in idling at less high learned values in partial load: Unmetered sation values air in intake manifold region possible
Unmetered air between air mass meter

Chap. 24-2.
Remove fault.
and throttle valve

Injection valve blocked
Test injected quantity Chapter 24-2. Display field 1 and 2 high: Air mass meter Test wiring and plug connections to air
faulty mass meter -G70- according to current flow diagram.
Fuel pressure too low Unmetered air at the exhaust manifold
Test fuel pressure regulator and holding

pressure Chap. 24-2.
gasket
Lambda probe heater faulty or lambda
Test lambda probe -G39- and lambda control upstream of catalytic converter Chapter 24-4.
probe dirty
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01
Display group 033 Lambda control - Lambda probe upstream of catalytic converter
Reading measured value block 33 xx.x % 1 x.xx V 2 3
no display
Lambda probe voltage before catalyst Lambda control before catalyst
Note
Re display field 2:
Voltage signal Mixture rich (low level of residual ox-
ygen) is between 0.130...1.500 V.
Voltage signal Mixture rich (high level of residual ox-
ygen) is at approx. 1.500...4.800 V.
Analysis: Display group 033, display field 2 - lambda probe voltage upstream of catalytic converter
Display field: 1 constant 0.000...1.400 V or constant 1.600...3.600 V constant 3,600 V constant 0.000 V
01-6 page 4
Octavia 1997 < Readout on display 4 < Display field no display verter Chapter 24-4
Self-diagnosis VI
Specification
Analysis ---- 01-6 page 4 Chapter 01-5
1,401,60 V
-10,010,0 %
Rectifying fault
Testing lambda probe and lambda control upstream of catalytic con-
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01
Display group 034, diagnosis of lambda probe before catalytic converter (ageing test)
Mode basic setting 04 BFQ: Brake and accelerator pedal pressed simultaneously, engine running at fast idling AVU: Brake pedal depressed, engine running at high engine speed System in basic setting 34 xxxx rpm 1 xxx.x C 2 x.xxx 3 Text 4 < Display field Result of test of lambda probe ageing upstream of catalytic converter (Test OFF, Test ON, B1-S1 O.K., B1-S1 not O.K.) Disregard display Catalytic converter temperature Engine speed
1)
Specification B1-S1 O.K.
Analysis ---
--min. 350,0 C 2500...4000 rpm about 1400 rpm1)
-------
for engines with engine code AVU
Display group 036 Operational readiness of lambda probe downstream of catalytic converter
Mode basic setting 04 Engine idling System in basic setting 36 x.xx V 1 Text 2 3 4 < Display field no display no display Test lambda probe downstream of catalytic converter (Test OFF, Test ON, B1-S2 O.K., B1 S2 n.o.k.) Lambda probe voltage after catalytic converter B1-S2 O.K. Specification Analysis ------ < Readout on display
0,001,00 V
01-6 page 6
Edition 10.04 S00.5135.52.20
Self-diagnosis VI
01-6 page 5
01
Octavia 1997
Voltage of the 4-pin lambda probe in U in mV A: Lambda probe voltage high rich mixture (fuel surplus or air shortage) high CO value B: Lambda probe voltage low lean mixture (fuel shortage or air surplus) low CO value
Analysis: Display group 036, display field 1 - Voltage of lambda probe, lambda probe downstream of catalytic converter
Display -V.A.G 1552 constant 1,10 V

Short circuit to positive caused by: Lamb-
Rectifying fault
da probe, lambda probe cable, earth lead, engine control unit lambda probe cable, earth lead, engine control unit probe, lambda probe cable, earth lead, engine control unit
constant 0.00 V
Short circuit to earth caused by: Lambda
Display group 041 Lambda probe heater

Reading measured value block 41 xxxx 1 Text 2 xxxx 3
Text 4
Internal resistance of lambda probe downstream of catalytic converter
Heater of lambda probe upstream of catalytic converter (Heating.bC.OFF/heating.bC.ON) Internal resistance of lambda probe upstream of catalytic converter
01-6 page 6
< Readout on display < Display field Heater of lambda probe downstream of catalytic converter (Heating.aC.OFF, heating.aC.ON) ----Self-diagnosis VI
constant between 0.40 ...0.50 V
Line interruption through: Lambda probe,
Test lambda probe -G130- and lambda

control downstream of catalytic converter Chapter 24-4.
Specification Htg.bC.ON
Analysis ---
-----
Htg.bC.ON
---
Edition 10.04 S00.5135.52.20
Octavia 1997
01
Display group 043, diagnosis of lambda probe after the catalytic converter (ageing test)
Mode basic setting 04 BFQ: Brake and accelerator pedal pressed simultaneously, engine running at fast idling AVU: Brake pedal depressed, engine running at high engine speed System in basic setting 43 xxxx rpm 1 xxx.x C 2 x.xx V 3 Text 4 < Display field Check result of ageing test of lambda probe downstream of catalytic converter (Test OFF, Test ON, B1-S2 O.K., B1-S2 N.O.K.) Lambda probe voltage after catalytic converter Catalytic converter temperature Engine speed
1)
Specification B1-S2 O.K.
Analysis ---
0,001,00 V min. 200,0 C 2500...4000 rpm about 1400 rpm1)
-------
Display group 046, diagnosis of the catalytic converter efficiency

Mode basic setting 04 BFQ: Brake and accelerator pedal pressed simultaneously, engine running at fast idling AVU: Engine runs in higher speed System in basic setting 46 xxxx rpm 1 xxx.x C 2 x.xx 3 Text 4 < Display field Result of catalytic converter test (Test OFF, Test ON, Cat B1 O.K., Cat B1 N.O.K.) Catalyst efficiency Catalytic converter temperature Engine speed
1)
Specification Cat B1 O.K.
Analysis ---
0,501,00 min. 400,0 C 2500...4000 rpm 2100 4500 rpm1)
-------
Edition 10.04 S00.5135.52.20
Self-diagnosis VI
01-6 page 7
01
Display group 050 Engine speed increase when AC on

Reading measured value block 50 xxx rpm 1 xxx rpm 2 Text 3
Text 4
Operating condition of air conditioning system Engine speed (idling speed - specified value) Engine speed (actual value)
Note
Re display field 2:
What is displayed is the specified engine speed (value computed internally in control unit in line with temperature)
specified by the engine control unit.

Re display field 4:
On vehicles not fitted with air conditioning system Compr. OFF is always displayed.
Display group 053 Engine speed increase with increased alternator load
Reading measured value block 53 xxxx rpm 1 xxxx rpm 2 xx.x V 3
xxx.x % 4
Supply voltage of the engine control unit Engine speed (idling speed - specified value) Engine speed (actual value)
Note
Re display field 4:
The readout is dependent on the particular electrical components which are switched on, e.g. rear window heater,
blower, seat heater etc.
01-6 page 8

Octavia 1997 < Readout on display < Display field Operating state of AC compressor < Readout on display < Display field Alternator load
Self-diagnosis VI
Specification
Analysis ------ Chapter 01-5
Compr. ON or compr. OFF ON or OFF
640900 /rpm 640900 /rpm
Specification
Analysis -- Chapter 01-5 -- Chapter 01-5
0,0100,0 % 12,514,5 V
approx. 640...900/ rpm 640900 /rpm
Edition 10.04 S00.5135.52.20
Octavia 1997
Display group 054 Engine speed control

Driving Coolant temperature 80 C
Reading measured value block 54 xxx rpm 1 Text 2 xxx.x % 3
xxx.x % 4
Sender 1 for accelerator pedal position Operating condition (idling, partial load, enrichment, trailing throttle, full load) Engine speed
Display group 055 Idling speed stabilisation

Reading measured value block 55 xxxx rpm 1 xx % 2 xx.x % 3
xxxxx 4
Initialisation value idle stabilizer Idling regulator Engine speed (idling speed)
Note
Re display field 3:
The display shows to what extent the idling stabilizer has disinitialised from the constructively given mean value.
On a new engine the value is in the positive region because of the higher friction, on a run-in engine it is in the negative region.
Meaning of 5-digit numerical block

X X X X X Meaning 1 x 1 1
PAS pressure switch ON (steering wheel at limit stop) no meaning Gear engaged 1) Air conditioning switched on
1 Air conditioning compressor on

1)
Only on vehicles fitted with automatic gearbox
Edition 10.04 S00.5135.52.20

< Readout on display < Display field Throttle valve angle (potentiometer 1 -G187-) --< Readout on display < Display field Operating conditions xxxxx
Self-diagnosis VI
01
Specification
Analysis ---------
0,0100,0 % 0,0100,0 %
6406500 /rpm
Specification
Analysis 01-6 page 9 ---- Chapter 01-5
-10,010,0 % -1020 %
640900 /rpm
01-6 page 9
01
Display group 056 Idling speed stabilisation

Reading measured value block 56 xxxx rpm 1 xxxx rpm 2 xx % 3
xxxxx 4
Idling regulator Engine speed (actual value)
Engine speed (idling speed - specified value)
Note
Re display field 2:
What is displayed is the specified engine speed (value computed internally in control unit in line with temperature)
specified by the engine control unit.
Display group 060 the EPC system

Mode basic setting 04 Ignition on, engine stopped System in basic setting 60 xx.x % 1 xx.x % 2 x 3
Text 4
Adaption status
Throttle valve angle (potentiometer 2 -G188-) Throttle valve angle (potentiometer 1 -G187-)
Note
to display group 060:
The adaptation of the throttle valve control unit occurs with the ignition switched on. The engine control unit is adjusted to the throttle valve control unit by selecting display group 060 under function
04 Basic setting. This adjustment must always be performed if a different throttle valve control unit (or completely different engine) or a different engine control unit has been fitted.
The specifications stated in display fields 1 and 2 are not fully utilised in this process. During adaptation the counter in display field 3 counts up to 9.
01-6 page 10

Octavia 1997 < Readout on display < Display field Operating conditions xxxxx < Readout on display < Display field Adaption status (ADP runs, ADP O.K. or ERROR) ADP o.k. 09
Self-diagnosis VI
Specification -1020 %
Analysis 01-6 page 9 -------
640900 /rpm 640900 /rpm
Specification
Analysis ---------
100,00,0 % 0,0100,0 %
Edition 10.04 S00.5135.52.20
Octavia 1997
Display group 062 Engine speed control EPC system

Ignition on, engine stopped Reading measured value block 62 xx.x % 1 xx.x % 2 xx.x % 3
xx.x % 4
Sender 1 for accelerator pedal position -G79Throttle valve angle (potentiometer 2 -G188-) Throttle valve angle (potentiometer 1 -G187-)
Note
The potentiometer on the throttle valve control unit and of the pedal value sensor are duplicated for safety reasons.
The engine control unit constantly verifies the plausibility of the potentiometers. celerator pedal position -G79-. always be approx. 100 %.
The value of sensor -2 for accelerator pedal position -G185- must always be half of the value of sender 1 for ac The potentiometers of the throttle valve control unit contra-rotate. The value of both potentiometers together must The specifications stated are not fully utilised.
Display group 063 Kickdown adaptation
Only on vehicles fitted with automatic gearbox Mode basic setting 04 Ignition on, engine stopped System in basic setting 63 xx.x % 1 xx.x % 2 Text 3
Text 4
Kick-down switch
Sender 2 for accelerator pedal position -G185Sender 1 for accelerator pedal position -G79-
Note
Re display field 4:
If actuated appears in display in the display field 4, depress the accelerator pedal fully and hold it in this position.
The test is finished when ADP O.K. appears in the display.
Edition 10.04 S00.5135.52.20

< Readout on display < Display field Sender 2 for accelerator pedal position -G185< Readout on display < Display field Operating conditions (ERROR, actuated, ADP runs, ADP O.K.) ADP o.k. Kickdown ----Self-diagnosis VI
01
Specification 3,048,0 % 6,096,0 % 97,03,0 %
Analysis ---------
3,097,0 %
Specification
Analysis Chapter 24-6
-------
01-6 page 11
01
Octavia 1997
Display group 066 cruise control system (only on vehicles with cruise control system)
Engine idling Reading measured value block 66 xxx km/h 1 xxxx 2 xxx km/h 3 xxxx 4 < Display field CCS switch position Driving speed (nominal), last value stored by the CCS Switch position of brake, clutch and CCS Vehicle speed (actual value) Specification xxxx or 0000xxxx --xxxx or 0000xxxx 0 km/h Analysis 01-6 page 12 -- 01-6 page 12 --< Readout on display
Analysis: Display group 066, display field 2 - switch for brake, clutch and CCS
X 1
X 1
Meaning Brake pedal depressed (brake light switch) Brake pedal depressed (brake switch) Clutch depressed (if automatic gearbox fitted: brake pedal depressed) CCS released
1 1
Analysis: Display group 066, display field 4 switch position of CCS

X 1 1 0 0 X X X Meaning Switch -B- to RES Switch -A- pressed (switch -B- to ON) Switch -B- to OFF (not locked or locked) Switch -B- to OFF (only if locked)
01-6 page 12
Self-diagnosis VI
Edition 10.04 S00.5135.52.20
Octavia 1997
Display group 070 Diagnosis of activated charcoal filter system (tank vent system)
Mode basic setting 04 Engine idling
Coolant temperature minimum 60 C System in basic setting 70 xxx.x % 1 xx.x % 2 xx.x % 3
Text 4
Idling speed controller variation during TVV diagnosis Lambda controller variation during TVV diagnosis
On/Off ratio of solenoid valve 1 for activated charcoal filter
Note
TVV means solenoid valve 1 for activated charcoal filter system. Diagnosis can only be initiated once each time the engine is started.
Note
Re display field 2:
Lambda regulation - deviation in the negative range: activated charcoal filter full.
Lambda regulation - deviation in the positive range: activated charcoal filter empty.
Display group 074 EGR positioner adaption

Mode basic setting 04 Ignition on, engine stopped System in basic setting 74 x.x V 1 x.x V 2 xxx.x % 3
Text 4
Current poti value Max. stop Zero position
Edition 10.04 S00.5135.52.20

< Readout on display < Display field Result of diagnosis (Test ON, Test OFF, TVV O.K., TVV N.O.K.) TVV o.k. < Readout on display < Display field Adaption status (ADP runs, ADP O.K. or ERROR) ADP o.k.
Self-diagnosis VI
01
Specification
Analysis ---
-8,08,0 %
-------
-10,07,0 %
0,0100,0 %
Specification
Analysis ---
0,0100,0 % 3,04,8 V 0,31.5 V
-------
01-6 page 13
01
Note
Octavia 1997
The adaptation of the exhaust gas recirculation valve occurs with the ignition on.
The engine control unit is adapted to the exhaust gas recirculation valve by selecting display group 074 under func-
tion 04 Basic position. This adaption must always be performed if another EGR valve (or completely different engine) or another engine control unit has been installed.
Display group 075 - Exhaust gas recirculation

Mode basic setting 04 Engine idling System in basic setting 75 xxxx rpm 1 xxx % 2 xxx.x % 3
Text 4
Valve stroke difference Engine speed (idling speed)
Opening degree potentiometer value
Display group 077 Diagnosis of secondary air injection system

Mode basic setting 04
BFQ: Brake and accelerator pedal pressed simultaneously, engine running at fast idling AVU: Brake pedal depressed, engine running at high engine speed System in basic setting 77 xxxx rpm 1 2 3 < Readout on display
Text 4
no meaning no meaning Engine speed (idling speed)
01-6 page 14

< Readout on display < Display field Result of the diagnosis (Test ON / Test OFF / Syst. O.K. / Syst. N.O.K.) Syst. o.k. < Display field Result of the diagnosis (Test ON / Test OFF / Syst. O.K. / Syst. N.O.K., interruption) Syst. o.k. ----Self-diagnosis VI
Specification
Analysis ---
-10,025,0 % 0,0100,0 %
---- Chapter 01-5
640900 /rpm
Specification
Analysis ---
-------
approx. 1400 rpm
Edition 10.04 S00.5135.52.20
Octavia 1997
Display group 095 Single-stage intake manifold changeover

Reading measured value block 95 xxxx rpm 1 xx.x % 2 xxx.x C 3
Text 4
Coolant temperature Load Engine speed (idling speed)
Note
Re display field 4:
If the throttle is depressed at approx. 2000 rpm, the status must jump from OFF to ON.
Display group 100 - readiness code

Reading measured value block 100 xxxxxxxx 1 xxx.x C 2 xxx s 3
xxxxxxxx 4
Time since engine start Coolant temperature Readiness code
Meaning of the digits in the 8-digit numerical block, display field 1 - readiness code
The readiness code is only generated when all display positions are at 0. X 0 0 0 0 0 0 0 0 X X X X X X X Checked system
Edition 10.04 S00.5135.52.20

< Readout on display < Display field Specification ON or OFF Status of intake manifold changeover --< Readout on display < Display field Specification ----Diagnosis status 00000000 Exhaust gas recirculation Lambda probe heater Lambda probes Secondary air system Activated charcoal filter (tank vent system) Catalytic converter
Self-diagnosis VI
01
Analysis -- Chapter 01-5 -- Chapter 01-5
80,0115.0 C 640900 /rpm
Analysis ---- Chapter 01-5 01-6 page 15
80,0115.0 C
Air conditioning system (currently no diagnosis/always 0)
Catalytic converter heating (no diagnosis at present/always 0)
01-6 page 15
01
Octavia 1997
Display group 120 Traction control system

Driving Reading measured value block 120 xxxx rpm 1 xxx Nm 2 xxx Nm 3 Text 4 < Display field Status Actual engine load Nominal engine load Engine speed Specification TCS active / TCS n. active 0260 Nm 0399 Nm 6406500 /rpm Analysis --------< Readout on display
Display group 122 Gearbox (only automatic gearbox)

Driving Reading measured value block 122 xxxx rpm 1 xxx Nm 2 xxx Nm 3 Text 4 < Display field Status Actual engine load Nominal engine load Engine speed Specification Engine ctl./ no ctl. 0260 Nm 0399 Nm 6406500 /rpm Analysis --------< Readout on display
Display group 125 CAN databus - Messages

For engines with engine code BFQ
Reading measured value block 125 Text 1 Text 2 Text 3
Text 4
< Display field Status of the air-conditioning system
Specification Clima 1 Combi 1 ABS 1 Gearbox 11)
Analysis -- 01-6 page 17 01-6 page 17 01-6 page 17
Status of the dash panel insert Status ABS Status gearbox

1)
For models with an automatic gearbox

01-6 page 16
Self-diagnosis VI
Edition 10.04 S00.5135.52.20
Octavia 1997
Reading measured value block 125 Text 1 Text 2 Text 3
Text 4
Status of the dash panel insert Status gearbox Status ABS

1)
For models with an automatic gearbox

For engines with engine code BFQ Reading measured value block 126 Text 1 2 3
Status airbag -----
Note
to the display groups 125 and 126:
Specification = 1 means: Connection to the CAN databus cables - control unit.
Specification = 0 means: No connection to the CAN databus cables - control unit.
Analysis: Display groups 125 and 126
Display -V.A.G 1552 if 0 displayed instead of 1
CAN databus connection defective
no CAN databus cables used - control
unit unit
CAN databus cables defective - control
Edition 10.04 S00.5135.52.20

< Readout on display < Display field Status airbag Airbag 1 Combi 1 ABS 1 < Readout on display 4 < Display field ----Airbag 1 ----Possible cause of fault
Self-diagnosis VI
01
Specification
Analysis -- 01-6 page 17 01-6 page 17 01-6 page 17
Gearbox 11)
Specification
Analysis -- 01-6 page 17 -----
Rectifying fault
Perform the automatic test sequence for

interrogation of all fault memories.
01-6 page 17
01
Display group 130 Diagnosis of mapped cooling

Engine idling AC switched off Reading measured value block 130 xxx.x C 1 xxx.x C 2 xx.x % 3
Text 4
On/off ratio of thermostat Coolant temperature engine outlet
Coolant temperature radiator outlet
Note
The coolant temperature at engine outlet must always be higher than at radiator outlet.

Engine idling AC switched off Reading measured value block 131 xxx.x C 1 xxx.x C 2 xxx.x % 3
xxx.x % 4
Coolant temperature radiator outlet
Coolant temperature at engine outlet (specified temperature) Coolant temperature at engine outlet (specified temperature)
Note
The coolant temperature at engine outlet must always be higher than at radiator outlet.
01-6 page 18

Octavia 1997 < Readout on display < Display field Result of the diagnosis (Test ON, Test OFF, Syst. O.K., Syst. N.O.K.) Syst. o.k. 0100 % 0100 C < Readout on display < Display field On/off ratio of thermostat
Self-diagnosis VI
Specification
Analysis ---
-------
80115 C
Specification
Analysis ---------
0,0100,0 %
0,0100,0 C 0,0115.0 C
80,0115.0 C
Edition 10.04 S00.5135.52.20
Octavia 1997

Engine idling AC switched off Reading measured value block 132 xxx.x C 1 xxx C 2 xx.x V 3
Text 4
Heating feed potentiometer -G267-
Temperature difference engine and radiator outlet Coolant temperature at radiator outlet (specified temperature)
1)
on vehicles fitted with Climatronic 5.1 V
Status of coolant regulation

X 1 1 x 1 1 1 X X X X X
Checked system
1. Fan level active
2. Fan level active
Regulator variation: 0 > spec. temp., 1 < act. temp. Fan actuation active Fault present Thermostat actuation active
Note
to bit 1 and 2:
The fan stages may also be actuated by the air conditioning system.
Edition 10.04 S00.5135.52.20
< Readout on display < Display field Status of coolant regulation xxxxxx 0,24.8 V 0110 C --Self-diagnosis VI
01
Specification
1)
Analysis 01-6 page 19 -------
01-6 page 19
01
Octavia 1997
01-6 page 20
Self-diagnosis VI
Edition 10.04 S00.5135.52.20
Octavia 1997
24
24 Fuel Formation, Injection

24-1 Fuel Injection System
Safety measures
Caution!
The fuel system is under pressure! Place a cloth around the connecting point before releasing hose connections or when opening the system. Then reduce the pressure by carefully removing the hose or cap.
Observe the following points to prevent injury to persons and/or damage to the injection and preheating system:
Do not touch or remove ignition leads with the engine
running or at start speed.

Ignition and plug connections must be switched off be-
fore disconnecting and re-connecting cables of the fuel injection and ignition system as well as of test equipment.
To operate the engine at start speed without it starting
(e.g. for a testing compression pressure), unplug connectors from the ignition unit and connectors from the injectors. After performing the work interrogate fault memory and erase.
Do not carry out engine wash unless the ignition is
switched off.
Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV control unit. If test and measuring devices are required during test drives observe the following:
Always secure the test and measuring devices on the
rear seat and have a second person operate them there. If the test and measuring equipment is operated from the front passenger seat, this can result in injuries to the persons sitting on that seat in the event of an accident which involves the front passenger airbag being deployed.
Rules of cleanliness
Pay careful attention to the following rules of cleanliness when working on the fuel supply or fuel injection systems:
Thoroughly clean the connection points and their sur-
roundings before releasing.

Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!

Carefully cover or close opened components if the re-
pair is not completed immediately.
Edition 10.04 S00.5135.52.20
Fuel Injection System
24-1 page 1
24
Octavia 1997
Only install clean parts: Remove spare parts from
their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. in tool boxes etc.).
When the system is open: avoid working with com-
pressed air. Avoid moving the vehicle.

Disconnected plug connections: Protect from dirt and
moisture. Plug together only if dry.
Overview of fitting locations

Note
Components marked with an * are tested by self-diagnosis Chap. 01-1. Components marked with ** are tested by final control diagnosis Chapter 01-1.
1 - Activated charcoal filter system solenoid valve 1 -N80-*/** K resistance: 2230 2 - Return-flow line K secure with spring strap clamps K to fuel delivery unit in fuel tank 3 - Feed line K secure with spring strap clamps K from fuel filter 4 - Camshaft position sensor -G163-* K for engines with engine code AVU K under top toothed belt guard K inspect Chapter 28-1 5 - Variable intake manifold changeover valve -N156- */** K inspect Chapter 24-3 6 - Top part of intake manifold K disassembling and assem30 bling 24-1 page 8 7 - Bottom part of intake manifold 8 - Connector, 81 pin K only insert or remove plug when the ignition is switched off K unlock before removing 9 - Engine control unit* K Fitting location: in plenum chamber K replacing Chapter 24-6 10 - Connector, 40 pin K only insert or remove plug when the ignition is switched off K unlock before removing 11 - Throttle valve control unit -J338-* K inspect Chapter 24-5 K 6-pin connector
C B
A D
24-1 page 2
Edition 10.04 S00.5135.52.20
Octavia 1997
24
12 -
13 -
14 15 -
16 -
17 -
18 -
19 20 -
21 22 -
23 24 25 26 -
27 -
K contacts gold-plated Camshaft position sensor -G163-* K for engines with engine code BFQ K at rear of cylinder head K inspect Chapter 28-1 EGR valve -N18- */** K with EGR potentiometer -G212K 6-pin connector K Adaptation Chap. 24-6 Combination valve K Secondary air pump 1.6 l/75 kW Engine, Mechanical Components; Rep. Gr. 26 Protective housing for relays and fuses K installation position: Secondary air injection pump relay -J299- */** Power supply of Simos engine control unit -J363K only on vehicles fitted with automatic gearbox Fuse for brake vacuum pump -V192 Fuse for secondary air injection pump motor -V101coolant temperature sender -G62-* K green K for engine control unit K with coolant temperature sender -G2K resistances 24-1 page 10 Brake vacuum pump -V192- with brake servo unit control unit -J542- (only on vehicles fitted with automatic gearbox) */** K inspect Chapter 24-2 Air mass meter -G70- with intake air temperature sender -G42- * K contacts of sender and of connector gold-plated K resistances for intake air temperature sender -G42- 24-1 page 9 Air filter K disassembling and assembling 24-1 page 9 Power output stage -N122- with ignition coil -N, N128K with identification for ignition leads, do not switch K resistances Chapter 28-1 Engine speed sender -G28-* K resistance: 7301000 Injection valves -N30N33-* K resistance: 1217 (at about 20 C) K test injected quantity, leak tightness and spray pattern of injectors Chapter 24-2. Secondary air injection pump motor -V101- */** K Secondary air system: 1.6 l/75 kW Engine - Mechanical Components; Rep. Gr. 26 Knock sensor I -G61-* K contacts of sender and of connector gold-plated Fuel pressure regulator K inspect Chapter 24-2 4-pin connector K Brown K for lambda probe heater -Z29- and lambda probe downstream of catalytic converter -G130K on underside of vehicle on right Lambda probe downstream of catalytic converter -G130-, 50 Nm* K only coat thread with hot screw paste G 052 112 A3; the paste must not get into the slot of the probe body. K Test lambda probe -G130- and lambda control downstream of catalytic converter Chapter 24-4
Edition 10.04 S00.5135.52.20
24-1 page 3
24
Octavia 1997
28 - 6-pin connector K black K for lambda probe heater -Z19- and lambda probe upstream of catalytic converter -G39K on underside of vehicle on right 29 - Lambda probe upstream of catalytic converter -G39 -, 50 Nm* K Fitting location: in the exhaust manifold K only coat thread with hot screw paste G 052 112 A3; the paste must not get into the slot of the probe body. K Test lambda probe -G39- and lambda control upstream of catalytic converter Chapter 24-4 30 - PAS pressure switch -F88- *
Fig. 1:
Pedal assembly - installed position
1 - Clutch pedal switch -F362 - Brake light switch -F- and Brake pedal switch -F473 - Accelerator pedal position sender -G79- and accelerator pedal position sender 2 -G185-
3 2
General notes on the injection system

Repairing the ignition Rep. Gr. 28. The engine control unit is equipped with a self-diagnosis system. Before repairs and also for fault finding, first of all interrogate the fault memory. Also check the vacuum hoses and connections (unmetered air). A minimum voltage of 11.5 V is required for perfect functioning of the electrical components. If after fault finding, repair or inspection of components the engine starts briefly and then stops, it is possible that the immobiliser blocks the 4AV control unit. In this case the fault memory must be interrogated and if necessary the control unit must be adapted. Certain inspections may cause the control unit to detect and store a fault. It is therefore necessary to interrogate the fault memory after having completed all inspections and repairs, and if necessary erase Chapter 01-1. Safety measures 24-1 page 1. Cleanliless rules 24-1 page 1. Test data, spark plugs Inspection and Maintenance.
1
S24-0459
24-1 page 4
Edition 10.04 S00.5135.52.20
Octavia 1997
24
Removing and installing parts of the injection system

Note
Components marked with an * are tested by self-diagnosis Chap. 01-1.

1 - Air filter K disassembling and assembling 24-1 page 9 2 - 6 Nm 3 - 10 Nm 4 - 3 Nm 5 - Bottom part of intake manifold 6 - Feed line K white K secured with spring strap clip K from fuel filter 1.6 l/75 Engine, Mechanical Components; Rep. Gr. 20 7 - Return-flow line K blue K secured with spring strap clip K to fuel delivery unit in fuel tank 1.6 l/75 kW Engine, Mechanical Components; Rep. Gr. 20 8 - Fuel rail with injection valves K disassembling and assembling 24-1 page 7 9 - 3-pin plug connection K for engines with engine code AVU K black K for camshaft position sensor -G16310 - 15 Nm 11 - Connector K for coolant temperature sender -G62K 4-pin K black K contacts gold-plated 12 - coolant temperature sender -G62-* K green K with coolant temperature sender -G2K resistances 24-1 page 10 K before removing, reduce pressure in cooling system if necessary 13 - O-ring K replace if damaged 14 - Retaining clip K check tightness 15 - Gasket ring K replace 16 - Connector K black, 2 pin
Edition 10.04 S00.5135.52.20
24-1 page 5
24
17 18 -
Octavia 1997
19 20 21 -
22 -
23 24 25 26 27 28 29 30 -
31 32 33 -
34 -
35 36 -
37 38 39 -
40 41 -
K for injection valve -N30...N33Gasket ring Connector K black, 2 pin K for variable intake manifold changeover valve -N156Cable rail Body-bound rivet Top part of intake manifold K with variable intake manifold changeover K disassembling and assembling 24-1 page 8 3-pin plug connection K grey K for engine speed sender K Fitting location: close to dipstick Engine speed sender -G28-* K Resistance 730...1000 Support K between intake manifold and cylinder head 8 Nm K for attaching vent connection Rubber bush 8 Nm To activated charcoal filter solenoid valve 1 -N80K Activated charcoal filter 1.6 l/75 kW Engine, Mechanical Components; Rep. Gr. 20 From heater feed Connector K 6-pin K contacts gold-plated K for throttle valve control unit -J338To T-connection and on to coolant expansion bottle 10 Nm K for engines with engine code BFQ Camshaft position sensor -G163K for engines with engine code BFQ K inspect Chapter 28-1 Connector K for engines with engine code BFQ K 3-pin K for camshaft position sensor -G163To the brake servo unit Gasket ring K for engines with engine code BFQ K replace if damaged K before fitting moisten with clean engine oil Gasket K replace From exhaust gas recirculation valve Air intake hose K with crankcase ventilation valve K with crankcase ventilation with heating resistor (only for models with optional equipment) For housing ventilation To EGR valve -N18K clean air connection to fresh air supply
Fuel Injection System Edition 10.04 S00.5135.52.20
24-1 page 6
Octavia 1997
24
42 - To secondary air pump 43 - Air mass meter -G70- with intake air temperature sender -G42- * K contacts of sender and of connector gold-plated K resistances for intake air temperature sender -G42- 24-1 page 9
Disassembling and assembling fuel distributor with injectors

Note

1 - Retaining clip K check tightness on the injection valve and fuel distributor 2 - Fuel distributor 3 - Injection valves -N30N33 -* K test injected quantity, leak tightness and spray pattern of injectors Chapter 24-2. K resistance: 1217 (at about 20 C) 4 - O-ring K replace K before fitting moisten lightly with clean engine oil 5 - Fuel pressure regulator K inspect Chapter 24-2
S24-0469
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Disassembling and assembling top part of intake manifold

Note
Components marked with an * are tested by self-diagnosis Chap. 01-1. Components marked with ** are tested by final control diagnosis Chapter 01-1.
1 - 8 Nm 2 - Throttle valve control unit -J338-* K 6-pin connector K contacts gold-plated K inspect Chapter 24-5 K if replaced adapt engine control unit Chapter 24-6 K if replaced, adapt automatic gearbox control unit Automatic Gearbox; Rep. Gr. 01 3 - Gasket ring K replace 4 - Pressure relief valve K protects intake manifold from damage if excess pressure exists 5 - Top part of intake manifold 6 - Body-bound rivet 7 - Variable intake manifold changeover valve -N156- */** K inspect Chapter 24-3
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Disassembling and assembling the air filter

Note

1 - Air mass meter -G70- with intake air temperature sender -G42- * K resistances for intake air temperature sender -G42 24-1 page 9 2 - Gasket ring 3 - 6 Nm 4 - Air filter top part 5 - Filter insert 6 - 10 Nm 7 - Air filter bottom part 8 - Air deflector 9 - Air intake hose K for secondary air pump 10 - Ventilation hose K for exhaust gas recirculation valve
Resistances for intake air temperature sender -G42The nominal value in field -A- applies for temperature range 0...50 C, nominal value in field -B- applies for temperature range 50...100 C. Read out examples:
30 C is within the range -A- and equals a resistance
of 1.5...2.0 k.
80 C is in range -B- and corresponds to a resistance
of 275...375 .
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Check resistance values of the intake manifold temperature sender -G42- between contacts 2 + 4.
Resistances for the coolant temperature sender -G62The nominal value in field -A- applies for temperature range 0...50 C, nominal value in field -B- applies for temperature range 50...100 C.
Read out examples:

30 C is within the range -A- and equals a resistance
of 1500...2000 k.
80 C is in range -B- and corresponds to a resistance
of 275...375 .
Test the resistance of the coolant temperature sender

-G62- between contacts C (signal) and D (earth).
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24-2
Testing components
Test wiring and components with Test box -V.A.G 1598/31The test box -V.A.G 1598/31- is designed in such a way that it can be simultaneously connected to the wiring loom of the engine control unit and to the actual engine control unit. The advantage being that the electronic engine control remains fully operational with the test box connected (e.g. measuring signals while the engine is running). Whether the control unit is additionally connected to the test box or not, is indicated in the particular test procedure. Always use the measuring tool set -V.A.G 1594 A, B oder C- to connect the measuring tools (e.g. handheld multimeter -V.A.G 1715- etc.). The contact numbers of the connector of the control unit and the socket numbers of the test box -V.A.G 1598/31are identical. Special tools, test and measuring equipment and auxiliary items required
Test box -V.A.G 1598/31-
WARNING!
To avoid damaging the electronic components, switch on the relevant measuring range before connecting the measuring cables and comply with the test conditions.
Remove wiper arm Electrical System; Rep. Gr. 92. Remove the cooling water tank cover Body Work;
Rep. Gr. 66.
Release the connector catches and unplug the control

unit connectors.
Connect test box -V.A.G 1598/31- to both connectors

of the wiring loom. Earth clip should be connected to the test box and to battery negative. Whether the control unit is additionally connected to the test box or not, is indicated in the particular test procedure.
Perform test as described in the relevant repair sequences. Note
It is therefore necessary to interrogate the fault memory after reconnecting the engine control unit, and if necessary erase Chapter 01-1.
Edition 10.04 S00.5135.52.20
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Octavia 1997
Inspecting the injection rate, tightness and jet formation of the injectors
Hand multimeter (e.g. -V.A.G 1348/2B-) Digital potentiometer (e.g. -V.A.G 1630-)
Test condition
Fuel pump relay o.k., testing Chap. 01-1.

Testing jet formation and tightness
Remove the upper part of the intake manifold

Chapter 24-1.
Remove the fuel rail together with the installed injec-
tors Chapter 24-1. The fuel hoses remain connected. perature sender -G62- -2-.
Unplug the 4-pin connector -1- from the coolant tem Set digital potentiometer -V.A.G 1630- side A to 15 k
and connect to the unplugged connector contact 3 and 4 using auxiliary cables.
Unplug the 4-pin connector -1- from the power output

stage -N122- -2-.
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Testing components
Edition 10.04 S00.5135.52.20
Octavia 1997
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Hold the injectors in the measuring glasses. Operate starter (2nd person required). The injectors
must spray in a pulsing action in line with firing order.
Switch ignition off and inspect injectors for leaks. No

more than 2 drops/min may trickle out. Note
Always fit new seals. If injectors are replaced, erase the learned values and
re-adapt engine control unit Chapter 24-6.
Testing injection rate

Note
When testing the injection rate also check the jet formation. The jet must be the same for all valves.
Insert injector to be tested in a measuring glass. Connect one contact of injector to the battery earth. Connect the second contact of the injector to the remote control.
Connect terminal to battery positive (+).
Connect battery positive (+) and fuse socket No. 28

with adapter cable and adapter -V.A.G 1348/3-2-. The fuel delivery unit must start running.
Actuate the remote control for 30 seconds. Perform the measurement on all injectors. Once all four injectors have been driven, position the
graduated measuring glasses on an even base. Nominal value per injection valve: 87...95 ml.
If the measured value of one or more injectors is outside the tolerance value, disconnect the fuel pump and replace the defective injector (or defective injectors) Chapter 24-1. The injectors are installed in the reverse order. Pay attention to the following:
Replace the O-rings and all the injectors and moisten
lightly with clean engine oil.

Insert injectors vertically and into the correct position
in the fuel rail and secure with retaining clips.

Fit fuel distributor with the secured injection valves
onto the cylinder head and and screw up at the same time Chapter 24-1.
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The fuel pressure regulator regulates the fuel pressure in line with the intake manifold pressure. Special tools, test and measuring equipment and auxiliary items required
Pressure gauge appliancee.g. -V.A.G 1318 Adapter -V.A.G 1318/9 Adapter -V.A.G 1318/17-
Test sequence
Remove fuse no. 28 (fuel delivery unit) from the fuse

holder.
WARNING!
The fuel system is under pressure! Before opening the system lay cleaning cloths around the connection point. Reduce pressure by carefully releasing the connection point.
Disconnect the connection of the fuel supply hose -1(black or black marking) and catch fuel leaking out with cloth.
Connect up the pressure gauge appliance

-V.A.G 1318- with adapter -V.A.G 1318/9- and -V.A.G 1318/17- to the feed line the hose to the fuel rail.
Open shut-off cock of the pressure measuring device.

Lever points in direction of flow.
Plug fuse no. 28 (fuel delivery unit) into the fuse holder.
Start engine and run in idle. Measure fuel pressure.

Specified value: approx. 0.25 MPa (2.5 bar)
Detach vacuum hose -1- from fuel pressure regulator

-2-. Fuel pressure must rise to approx. 0.3 MPa (3.0 bar). If the specified value is not reached:
Test flow rate of fuel delivery unit 1.6 l/75 kW Engine, Mechanical Components; Rep. Gr. 20. If the specified value is reached:
Switch off ignition. Test for leaks and holding pressure. Observe pressure drop at gauge. A pressure of at least 0.2 MPa (2.0 bar) must be indicated on the gauge after 10 minutes. If the holding pressure drops below 0.2 MPa (2.0 bar):
24-2 page 4
Testing components
Edition 10.04 S00.5135.52.20
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Start engine and run in idle. After the pressure has been built up, switch ignition
off. Simultaneously connect the shut-off cock -arrowto the pressure gauge appliance .
Observe pressure drop at gauge.

If the pressure does not drop:
Test non-return valve of fuel delivery unit 1.6 l/75

kW Engine, Mechanical Components; Rep. Gr. 20 If the pressure again drops:
Inspect pressure measuring device for leaks. Inspect connections, O-rings on the fuel rail and injectors for leaks. If no leaks are found:
Replace the fuel pressure regulator.

Note
Before removing the pressure measuring device, place the cloth around the line connection and remove the fuse no. 28 (fuel delivery unit) from the fuse holder.
Testing the intake system for tightness (unmetered air)

Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3, 3A, 3B, oder 3C Engine leak search spray -G 001 800 A1-
Test condition
Coolant temperature must be at least 80 C.

Test sequence
Note
Because of the vacuum in the intake system the leak
search spray is sucked in with the unmetered air. The leak search spray reduces the ignition performance of the mixture. This results in a drop in engine speed and a change in the lambda probe control value.
You must comply with the safety instructions on the
box.
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
Enter function 08 read measured value block and

select display group 001. Readout on display:
Reading measured value block 700/min 85.0 C 1.5 % 1 -> 10111111
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Octavia 1997
Observe engine speed in display field 1 and readout

for lambda control upstream of catalytic converter in display field 3.
Systematically spray parts of the intake system with

engine leak search spray. If the engine speed drops or if the displayed lambda control value changes:
Press Enter
with Q .
.
0 6 for the function End output and confirm
Switch off ignition. Check the sprayed location of the intake system for
leaks and if necessary eliminate the fault.
Testing brake vacuum pump -V192The brake servo assistance system on vehicles fitted with automatic gearbox improves provision of the vacuum required. The brake vacuum pump -V192- and the brake servo assistance control unit -J542- form a single unit. Special tools, test and measuring equipment and auxiliary items required
Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C Hand multimeter (e.g. -V.A.G 1715-) Diode test lamp (e.g. -V.A.G 1527B-) Adapter cable set (e.g. -V.A.G 1594 A, B oder C-) Test box -V.A.G 1598/31-
Check for proper operation
Initiate final control diagnosis and select vacuum

pump for brakes -V192- Chapter 01-1. If the pump does not run:
Test actuation 24-2 page 6, voltage supply
24-2 page 7 and cables Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Test control
Unplug plug -1- from the vacuum pump -2-. Connect diode test lamp to contacts 1 and 2 of the
plug -1-.
Switch on the ignition and initate an actuator diagnosis. The LED must flash. The LED flashes:
Proceed with the final control diagnosis up to the end.
24-2 page 6
Testing components
Edition 10.04 S00.5135.52.20
Octavia 1997
24
1 2
Switch off ignition. Check fuse -3- for the vacuum pump.
If fuse is o.k.:
Check voltage supply.

The LED does not flash:
Test wiring.
S24-0465
Check supply voltage
Connect multimeter for voltage measurement (terminal 30) to contacts 1 and 5. Specified value: approx. battery voltage
Connect multimeter for voltage measurement (terminal 15) to contacts 1 and 3.
Switch on ignition.
Specified value: approx. battery voltage If the specified values are reached:
Replace brake vacuum pump -V192- Chassis;

Rep. Gr. 47. If the specified values are not reached:
Test wiring Current Flow Diagrams, Electrical Fault

Finding and Fitting Locations.
Edition 10.04 S00.5135.52.20
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Testing components
Edition 10.04 S00.5135.52.20

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Octavia 1997
28
28 Ignition System
28-1 Ignition System
General notes on the ignition system

The engine control unit is equipped with a self-diagno-
sis system.
A minimum voltage of 11.5 V is required for perfect
functioning of the electrical components.

Certain inspections may cause the control unit to de-
tect and store a fault. It is therefore necessary to interrogate the fault memory after having completed all inspections and repairs, and if necessary delete.
If after fault finding, repair or inspection of compo-
nents the engine starts briefly and then stops, it is possible that the immobiliser blocks the 4AV control unit. In this case the fault memory must be interrogated and if necessary the control unit must be adapted.
Safety measures
Observe the following points to prevent injury to persons and/or damage to the injection and preheating system:
Do not touch or remove ignition leads with the engine
running or at start speed.

Disconnect and connect wires of the injection and pre-
heating system and measuring device wires when the ignition is switched off.
To operate the engine at start speed without it starting
(e.g. for a testing compression pressure), unplug connectors from the ignition unit and connectors from the injectors. After performing the work interrogate fault memory and erase.
Do not carry out engine wash unless the ignition is
switched off.
Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV control unit.
If the engine must be operated at start speed without
the engine starting:
Unplug 4-pin connector -1- from ignition transformer

-2-.
Edition 10.04 S00.5135.52.20
Ignition System
28-1 page 1
28
Octavia 1997
Removing and installing ignition system

1 - Ignition lead K 48 k K with shielded plug and sparkplug K Use extractor -T10112- to unplug spark plug connector. 2 - Ignition transformer -N, N128K with identification for ignition leads: A = Cylinder 1 B = Cylinder 2 C C = Cylinder 3 D = Cylinder 4 B K with power output stage -N122K resistances 28-1 page 3 3 - 10 Nm 4 - Connector K 4-pin 5 - Knock sensor -G61K contacts of sender and of connector gold-plated 6 - 3-pin plug connection K contacts gold-plated K black 7 - 20 Nm K The tightening torque influences the knock sensor function 8 - Spark plug, 20...30 Nm K type and electrode gap Inspection and Maintenance K use spark plug wrench, (e.g. -3122 B-) for removing and installing 9 - Connector K for engines with engine code AVU K for the camshaft position sensor -G163K contacts of sender and of connector gold-plated K 3-pin 10 - Bracket K for engines with engine code AVU K for camshaft position sensor -G16311 - Camshaft position sensor -G163K for engines with engine code AVU K check 28-1 page 3 12 - Camshaft sprocket K for engines with engine code letters AVU with trim for hall sender K removing and installing 1.6 l/75 kW Engine, Mechanical Components; Rep. Gr. 15 13 - 10 Nm K for engines with engine code AVU 14 - 100 Nm K to release and tighten use counterholder -3415-
A D
28-1 page 2
Ignition System
Edition 10.04 S00.5135.52.20
Octavia 1997
28
15 - 10 Nm K for engines with engine code BFQ 16 - Camshaft position sensor -G163K for engines with engine code BFQ K check 28-1 page 3 17 - Gasket ring K for engines with engine code BFQ K replace if damaged K before fitting moisten with clean engine oil 18 - Rotor K for engines with engine code BFQ K on the camshaft
Resistances of ignition coils

What is tested is the resistance between contacts 2 + 3 and 1 + 4. Specified value: 4.0...6.0 k (at approx. 20 C)
Inspecting the camshaft position sensor -G163The camshaft position sensor -G163- indicates the ignition position for cylinder 1. If it fails the knock control is deactivated and the ignition angle is slightly reduced as a cylinder assignment is no longer possible. Without sensor signal the engine runs on and can be started again:
In the event of a fault detection the engine control unit
generates an ignition spark per cylinder for each crankshaft rotation.

There is no noticeable effect on the injection if there is
a displacement of an engine revolution. Instead of occurring with the injection valve open the injection occurs "pre-engaged" (before the closed injection valve). This only has a very slight influence on the quality of the mixture formation. Note
The camshaft position sensor -G163- is identical to
the Hall sender -G40-.

The correct setting of the timing can be checked in
measured value block 012 Chapter 01-5.
Hand multimeter (e.g. -V.A.G 1715-) Adapter cable set (e.g. -V.A.G 1594 A, B oder C-) Test box -V.A.G 1598/31-
Edition 10.04 S00.5135.52.20
Ignition System
28-1 page 3
28
Test sequence
Octavia 1997
Unplug the plug on the camshaft position sensor

-G163- -arrow-. For engines with engine code BFQ
For engines with engine code AVU Continued for all engines
Switch on ignition. Connect up hand multimeter and measure the voltage

as follows:
For engines with engine code BFQ
28-1 page 4
Ignition System
Edition 10.04 S00.5135.52.20
Octavia 1997
28
For engines with engine code AVU 3-pin plug -1- on wiring loom, contact 1+3 If the specified value is not reached: Specification min. 4,5 V
1 2 3
1 2
Test wiring Current Flow Diagrams, Electrical Fault

Finding and Fitting Locations
S28-0124
Edition 10.04 S00.5135.52.20
Ignition System
28-1 page 5
28
Octavia 1997
28-1 page 6
Ignition System
Edition 10.04 S00.5135.52.20

Manual Skoda Octavia 1,6 75kW AVU BFQ

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1.6 l/75 kW Engine, Fuel Injection and Ignition System

List of Supplements to Workshop Manual

Edition 06.01 08.02 10.04

Article Number S00.5135.50.20 S00.5135.51.20 S00.5135.52.20

Edition 10.04 S00.5135.52.20

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Edition 10.04 S00.5135.52.20

1.6 l/75 kW Engine, Fuel Injection and Ignition System

24 Fuel Formation, Injection

Edition 10.04 S00.5135.52.20

Edition 10.04 S00.5135.52.20

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