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OCTAVIA 1997
2,0 l/85 kW Engine, Fuel Injection and Ignition System
List of Supplements to Workshop Manual
OCTAVIA 1997
Edition 02.00
Supplement 1 2 3
Edition 02.00 03.01 04.02 01.04
Subject Basic Edition Supplement to basic edition (completely replaces the basic edition) Changes for engine AZJ Modifications in the Rep. Gr. 01 and 24
Article Number S00.5128.50.20 S00.5128.51.20 S00.5128.52.20 S00.5128.53.20
Edition 01.04 S00.5128.53.20
List of Supplements
OCTAVIA 1997
List of Supplements
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
Table of Contents
01 Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 - Properties of the self-diagnosis ..................................................................... 01-1 - Technical data of self-diagnosis ..................................................................... 01-1 - Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics .............................................................................................. 01-1 - Interrogating and erasing fault memory ............................................................ 01-1 Self-diagnosis II ......................................................................................... 01-2 - Fault table, fault codes 16485...17736 ............................................................. 01-2 Self-diagnosis III ........................................................................................ 01-3 - Fault table, fault codes 17743...18101 ............................................................. 01-3 Self-diagnosis IV ....................................................................................... 01-4 - Actuator diagnosis ..................................................................................... 01-4 - Readiness code ........................................................................................ 01-4 - Reading readiness code .............................................................................. 01-4 - Generating readiness code .......................................................................... 01-4 Self-diagnosis V ........................................................................................ 01-5 - Reading measured value blocks, display groups 000 to 029 ................................... 01-5 Self-diagnosis VI ....................................................................................... 01-6 - Reading measured value block, display groups 030 to 062 .................................... 01-6 Self-diagnosis VII ....................................................................................... 01-7 - Reading measured value blocks, display groups 066 to 126 ................................... 01-7 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 1 1 1 1 1 1 3 4 4 1 1 1 1 1 1
24 Fuel Formation, Injection

Repairing the injection system ...................................................................... 24-1 - General Instructions ................................................................................... 24-1 - Safety instructions ..................................................................................... 24-1 - Rules of cleanliness ................................................................................... 24-1 - Individual components of system - Installation overview ........................................ 24-1 - Removing and installing parts of the injection system ........................................... 24-1 - Disassembling and assembling the air filter ....................................................... 24-1 - Disassembling and assembling bottom part of intake manifold ................................ 24-1 - Disassembling and assembling top part of intake manifold ..................................... 24-1 - Disassembling and assembling fuel distributor with injectors .................................. 24-1 Testing components ................................................................................... 24-2 - Testing cables with test box -V.A.G 1598/22- or -V.A.G 1598/31- ............................. 24-2 - Testing throttle valve control unit -J338- ........................................................... 24-2 - Testing accelerator pedal position sender ......................................................... 24-2 - Testing injected quantity and injectors for leaks .................................................. 24-2 - Testing fuel pressure regulator and holding pressure ........................................... 24-2 Check for proper operation .......................................................................... 24-3 - Testing lambda probe -G39- and lambda control upstream of catalytic converter .......... 24-3 - Testing lambda probe ageing upstream of catalytic converter -G39- ......................... 24-3 - Testing lambda probe -G130- and lambda control downstream of catalytic converter ..... 24-3 Engine control unit ..................................................................................... 24-4
Edition 01.04 S00.5128.53.20 Table of Contents
page page page page page page page page
1 1 1 2 2 5 8 8
page 10 page 11 page page page page page page page page page page page 1 1 1 2 3 5 1 1 2 4 1
OCTAVIA 1997
2,0 l/85 kW Engine, Fuel Injection and Ignition System page page page page page page page page page page page 1 2 3 4 5 6 7 1 1 1 3
- Testing voltage supply for engine control unit .................................................... 24-4 - Procedure if voltage supply interrupted ............................................................ 24-4 - Replacing engine control unit .. ...................................................................... 24-4 - Code the engine control unit (AEG, APK, AQY) .................................................. 24-4 - Deleting learned values from the engine control unit ............................................ 24-4 - Adjusting the engine control unit to the throttle valve control unit ............................. 24-4 - Adjusting the kick-down function .................................................................... 24-4 Testing auxiliary signals ............................................................................. 24-5 - Testing the speed signal ............................................................................. 24-5 - Testing databus (CAN bus) .......................................................................... 24-5 - Activating and deactivating cruise control system (CCS) ....................................... 24-5
28 Ignition System
Repairing the ignition system ....................................................................... 28-1 - General notes on the ignition system .............................................................. 28-1 - Safety measures ...................................................................................... 28-1 - Removing and installing parts of the ignition system ............................................ 28-1 - Testing camshaft position sensor -G40- ........................................................... 28-1 page page page page page 1 1 1 2 4
II
Table of Contents
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OCTAVIA 1997
01
01-2
Self-diagnosis II
Fault table, fault codes 16485...17736

Note The fault table is arranged according to the 5-digit fault code on the left. Faults related to the electronic throttle are indicated on the dash panel insert by the fault lamp for the electronic accelerator control EPC warning lamp. 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 vehicle system tester. If parts are output as faulty: First of all, test all the cables and plug connections to these components as well as the earth cables of the system according to the current flow diagram. Replace the component only if this test does not reveal any fault. This applies in particular if the fault is shown as sporadic (SP). Note 16486 = Fault denomination P0113 = next fault code (at present only applicable for USA) 035 = fault type as number air mass meter -G70- = current path or fault point defective Signal too small = designate fault type with text sporadically occurring fault = fault which does not occur often, e.g. loose contact
Readout on -V.A.G 1552 16485 Air mass meter -G70Implausible signal
Rectifying fault
Read measured value block, display group 002 Chapter 01-5 Check wiring to meter -G70- Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
16486 Air mass meter -G70-
Signal too low
Testing the intake system for tightness (unmetered air) Replace air filter element Read measured value block, display group 002 Chapter 01-5 Remove short-circuit or line interruption Current Flow Diagrams, Electrical Fault Finding and Fitting Locations Replace engine control unit Chapter 24-4 Test fuse 43 Read measured value block, display group 002 Chapter 01-5 Test wiring Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
16487 Air mass meter -G70-
Signal too high
Replace engine control unit Chapter 24-4

Edition 01.04 S00.5128.53.20 Self-diagnosis II
01-2 page 1
01
Readout on -V.A.G 1552 16496 Intake air temperature sender -G4216497 Intake air temperature sender -G4216500 Sender for the coolant temperature -G6216501 Sender for the coolant temperature -G6216502 Sender for the coolant temperature -G6216504 Throttle valve potentiometer -G6916505 Throttle valve potentiometer -G6916506 Throttle valve potentiometer -G6916507 Throttle valve potentiometer -G6916514 Bank 1 - probe 1 16515 Bank 1 - probe 1 16516 Bank 1 - probe 1 16517 Bank 1 - probe 1 16518 Bank 1 - probe 1 16519 Bank 1 - probe 1, heating circuit 16520 Bank 1 - probe 2 16521 Bank 1 - probe 2 16522 Bank 1 - probe 2 16523 Bank 1 - probe 2 16524 Bank 1 - probe 2 16525 Bank 1 - probe 2, heating circuit
OCTAVIA 1997
Rectifying fault Signal too low
Read measured value block, display group 004, display field 4

Chapter 01-5
Signal too high Implausible signal Signal too low
Test wiring Current Flow Diagrams, Electrical Fault Finding and

Fitting Locations
Replace engine control unit Chapter 24-4 Read measured value block, display group 001, display field 2
Chapter 01-5
Test coolant temperature sender Chapter 24-1 Check coolant regulator 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 19
Signal too high Electrical fault in the circuit Implausible signal Signal too low
Replace engine control unit Chapter 24-4 Test throttle valve control unit Chapter 24-2
Signal too high Electrical fault in the circuit Voltage too low Voltage too high Signal too slow No activity Electrical fault
Testing lambda probe and lambda control upstream of catalytic converter Chapter 24-3
Test lambda probe ageing Chapter 24-3
Testing lambda probe heater upstream of catalytic converter

Chapter 24-3
Electrical fault in the circuit Voltage too low Voltage too high Signal too slow No activity Electrical fault
Testing lambda probe and lambda control downstream of catalytic

converter Chapter 24-3
Test lambda probe heater downstream of catalytic converter

Chapter 24-3
01-2 page 2
Self-diagnosis II
Edition 01.04 S00.5128.53.20
OCTAVIA 1997 Readout on -V.A.G 1552 -
2,0 l/85 kW Engine, Fuel Injection and Ignition System Rectifying fault Malfunction
01
16554 Bank 1, fuel metering system 16555 Bank 1, fuel metering system
System too lean
Test fuel pressure regulator and holding pressure Chap. 24-2 Test injectors Chapter 01-4, Final control diagnosis Test fuel delivery unit 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 20
Inspect exhaust system for tightness 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26
Inspect tightness of the secondary air system 2.0 l/85 kW Engine,

Mechanical Components; Rep. Gr. 26
16556 Bank 1, fuel metering system
System too rich
Inspect vacuum lines for tightness Test intake system for tightness Test fuel pressure regulator and holding pressure Chap. 24-2 Test injected quantity Chapter 24-2 Test solenoid valve for activated charcoal filter Chapter 01-4, final control diagnosis
16585 Injector cyl. 1 -N3016586 Injector cyl. 2 -N3116587 Injector cyl. 3 -N3216588 Injector cyl. 4 -N3316603
Electrical fault in the circuit Electrical fault in the circuit Electrical fault in the circuit Electrical fault in the circuit Maximum engine speed exceeded Implausible signal Signal too low
Test injectors Chapter 01-4, Final control diagnosis
see fault code 16585
Rectify any mechanical damage Test throttle valve control unit Chapter 24-2
16605 Angle sender 2 for TV drive -G18816606 Angle sender 2 for TV drive -G18816607 Angle sender 2 for TV drive -G188-
Signal too high
16610 Implausible Sender 1/2 for accelera- signal tor pedal position -G79+ -G18516611 Sender for accelerator pedal position -G7916612 Sender for accelerator pedal position -G7916614 Fuel pump relay -J1716645 Injector cyl. 1 -N3016646 Injector cyl. 1 -N30Signal too low
Test accelerator pedal position sender Chapter 24-2
Signal too high Electrical fault in the circuit Short circuit to earth Short circuit to positive
Test fuel pump relay -J17- Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
Edition 01.04 S00.5128.53.20
Self-diagnosis II
01-2 page 3
01
Readout on -V.A.G 1552 16648 Injector cyl. 2 -N3116649 Injector cyl. 2 -N3116651 Injector cyl. 3 -N3216652 Injector cyl. 3 -N3216654 Injector cyl. 4 -N3316655 Injector cyl. 4 -N3316684 Combustion misfiring detected
OCTAVIA 1997
Rectifying fault Short circuit to earth Short circuit to positive Short circuit to earth Short circuit to positive Short circuit to earth Short circuit to positive see fault code 16645 see fault code 16646 see fault code 16645 see fault code 16646 see fault code 16645 see fault code 16646

Combustion misfiring detected Combustion misfiring detected Combustion misfiring detected Combustion misfiring detected Implausible signal No signal
Test injectors Chapter 01-4, Final control diagnosis Test ignition leads and spark plugs Chapter 28-1 Inspect ignition transformer Chapter 28-1 Read measured value block, display group 014 Chapter 01-5
16685 Cyl. 1 16686 Cyl. 2 16687 Cyl. 3 16688 Cyl. 4 16705 Engine speed sender -G2816706 Engine speed sender -G2816708 Knock control 16711 Knock sensor 1 -G6116712 Knock sensor 1 -G6116716 Knock sensor 2 -G6616717 Knock sensor 2 -G66-
Check engine speed sender -G28- Chapter 24-1
Malfunction Signal too low Signal too high Signal too low Signal too high
Inspecting knock sensors -G61- and -G66- Chap. 28-1. Read measured value block, display group 026 Chap. 01-5
16724 Incorrect asCamshaft position/ signment crankshaft position sensor
Test camshaft position sensor -G40- Chapter 28-1
01-2 page 4
Self-diagnosis II
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2,0 l/85 kW Engine, Fuel Injection and Ignition System Rectifying fault Implausible signal Signal too low
01
16725 Camshaft position sensor sender -G4016726 Camshaft position sensor sender -G4016727 Camshaft position sensor sender -G4016735 Ignition control cyl. 1
Signal too high Malfunction
Test ignition leads and spark plugs Chapter 28-1 Inspect ignition transformer Chapter 28-1 Read measured value block, display group 014 Chapter 01-5
16736 Ignition control cyl. 2 16737 Ignition control cyl. 3 16738 Ignition control cyl. 4 16795 Secondary air system
Malfunction Malfunction Malfunction Flow rate incorrect
Check secondary air pump 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26
Check secondary air pump 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26
Test combination valve 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26
Check secondary air injection valve 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26
Inspect hoses and connection pipes to individual components, and

between components 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26 16802 Secondary air pump relay -J29916804 Bank 1, catalytic converter system 16806 Bank 1, main catalytic converter 16824 Tank ventilation system 16825 Tank ventilation system 16885 Vehicle speed signal 16890 Idling control 16891 Idling control Malfunction
Test the relay or the secondary air pump Chapter 01-4, final control diagnosis
Efficiency too low
Generate readiness code Chapter 01-4 Check emission levels if the same faults are displayed Inspection
and Maintenance
Efficiency too low Malfunction Flow rate incorrect Implausible signal Speed under nominal value Speed above nominal value
Replace catalytic converter 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26
Test solenoid valve for activated charcoal filter Chapter 01-4, final
control diagnosis
Inspect hoses and connection pipes from fuel tank up to injection rail
2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 20
Test vehicle speed signal Chapter 24-5 Test throttle valve control unit Chapter 24-2 Replace intake air filter Test throttle valve control unit Chapter 24-2
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01-2 page 5
01
Readout on -V.A.G 1552 16894 Idling speed switch -F6016897 Immobilizer 16944 Voltage supply 16946 Voltage supply Malfunction
OCTAVIA 1997
Rectifying fault
Test throttle valve control unit Chapter 24-2 Replace engine control unit Chapter 24-4 Adapt engine control unit to electronic immobiliser Electrical System; Rep. Gr. 96.
incorrect code number Implausible signal Voltage too low
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations Inspect engine control unit power supply Chapter 24-4 procedure if voltage interrupted Chapter 24-4 Test alternator and battery Electrical System; Rep. Gr. 27 Inspect engine control unit power supply Chapter 24-4 Test alternator and battery Electrical System; Rep. Gr. 27 Read measured value block, display group 066 Chapter 01-7
16947 Voltage supply 16952 CCS switch -E4516955 Brake light switch -F
Voltage too high Implausible signal Implausible signal
Read measured value block, display group 066 Chapter 01-7 Check wiring and plug connections according to the current flow diagram
16984 Databus drive
missing message
Read measured value block, display groups 125 and 126 Chapter
01-7
16985 Control unit defective
Inspect databus Chapter 24-5 Perform automatic test sequence Chapter 01-1 Test earth cables according to current flow diagram Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations Malfunction
16986 Control unit programming 16988 Control unit defective 16989 Control unit defective 16990 Control unit defective 17022 Throttle valve control unit -J33817026 Knock control 17069 Main relay -J27117070 Main relay -J27117071 Main relay -J271-
Replace engine control unit Chapter 24-4 Check parts of the engine control unit and the gearbox control unit
and replace the control unit if necessary
Test earth cables according to current flow diagram Current Flow

Diagrams, Electrical Fault Finding and Fitting Locations
Replace engine control unit Chapter 24-4
Implausible signal Control unit defective Open circuit
Test throttle valve control unit Chapter 24-2 Replace engine control unit Chapter 24-4 Test the power supply relay -J271- for the engine control unit
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Short circuit to earth Short circuit to positive
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Self-diagnosis II
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2,0 l/85 kW Engine, Fuel Injection and Ignition System Rectifying fault Short circuit to positive Output too small Short circuit to positive System too lean System too rich Short circuit to earth Open circuit
01
17510 Bank 1 - probe 1, heating circuit 17511 Bank 1 - probe 1, heating circuit 17513 Bank 1 - probe 2, heating circuit 17519 Lambda control (Bench 1) 17520 Lambda control (Bench 1) 17523 Bank 1 - probe 1, heating circuit 17524 Bank 1 - probe 1, heating circuit 17525 Bank 1 - probe 2, heating circuit 17526 Bank 1 - probe 2, heating circuit

Chapter 24-3

Chapter 24-3
Test lambda probe -G39- and lambda control upstream of catalytic


Chapter 24-3
Short circuit to earth Open circuit

Chapter 24-3
System too 17535 Bank 1, mixture adapta- rich tion (mult.)
Test fuel pressure regulator and holding pressure Chap. 24-2 Test injected quantity Chapter 24-2 Test solenoid valve for activated charcoal filter Chapter 01-4, final
control diagnosis
System too 17536 Bank 1, mixture adapta- lean tion (mult.)
Test fuel pressure regulator and holding pressure Chap. 24-2 Test injected quantity Chapter 24-2 Test fuel delivery unit 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 20
Test intake system for tightness Inspect exhaust system for tightness 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26

Mechanical Components; Rep. Gr. 26 17549 Load detection 17550 Load detection 17551 Load detection implausible value Below limit Above limit
Inspect vacuum lines for leaks Test throttle valve control unit Chapter 24-2 Test accelerator pedal position sender Chapter 24-2
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01
Readout on -V.A.G 1552 17553 Air mass meter -G70-
OCTAVIA 1997
Rectifying fault Short circuit to positive
Read measured value block, display group 002 Chapter 01-5 Check wiring to meter -G70- Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
17557 Lambda control (Bench 1)
implausible control value

17559 Below leanBank 1, mixture adapta- ness limit tion range 1 17560 Below leanBank 1, mixture adapta- ness limit tion range 2
Testing the intake system for tightness (unmetered air) Inspect tightness of the secondary air system 2.0 l/85 kW Engine,
Test fuel pressure regulator and holding pressure Chap. 24-2 Test injected quantity Chapter 24-2 Test fuel delivery unit 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 20
17573 Above richBank 1, mixture adapta- ness limit tion range 1 17574 Above richBank 1, mixture adapta- ness limit tion range 2 17579 Angle sender 2 for TV drive -G18817580 Angle sender 2 for TV drive -G18817581 Angle sender 2 for TV drive -G18817584 Bank1, lambda correction according to catalytic converter 17586 Linear lambda probe/ pump current 17587 Linear lambda probe/ pump current 17588 Linear lambda probe/ pump current 17589 Linear lambda probe/ reference voltage 17590 Linear lambda probe/ reference voltage 17591 Linear lambda probe/ reference voltage Implausible signal Signal too low
control diagnosis
Check angle sender in measured value block, display group 060

Chapter 01-6
Test throttle valve control unit Chapter 24-2
Signal too high Regulating limit reached
Test lambda probe ageing -G39- upstream of catalytic converter

Chapter 24-3
Test lambda probe -G130- and lambda control downstream of catalytic converter Chapter 24-3 converter Chapter 24-3 Open circuit
Short circuit to earth Short circuit to positive Open circuit
Short circuit to earth Short circuit to positive
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2,0 l/85 kW Engine, Fuel Injection and Ignition System Rectifying fault Open circuit
01
17592 Linear lambda probe/ combined earth cable 17593 Linear lambda probe/ combined earth cable 17594 Linear lambda probe/ combined earth cable 17606 Bank 1 - probe 2, heating circuit 17621 Injector cyl. 1 -N3017622 Injector cyl. 2 -N3117623 Injector cyl. 3 -N3217624 Injector cyl. 4 -N3317633 Injector cyl. 1 -N3017634 Injector cyl. 2 -N3117635 Injector cyl. 3 -N3217636 Injector cyl. 4 -N3317645 Injector cyl. 1 -N3017646 Injector cyl. 2 -N3117647 Injector cyl. 3 -N3217648 Injector cyl. 4 -N3317704 Cooling system
Short circuit to earth Short circuit to positive Electrical fault
Test lambda probe -G130- and lambda control downstream of catalytic converter Chapter 24-3
Short circuit to positive Short circuit to positive Short circuit to positive Short circuit to positive Short circuit to earth Short circuit to earth Short circuit to earth Short circuit to earth Open circuit
Test injectors Chapter 01-4, Final control diagnosis Test fuse 32
Open circuit Open circuit Open circuit Fault see fault code 17645
Test coolant temperature sender Chapter 24-1 Check coolant regulator 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 19
17708 Combustion misfiring detected
Reason: Fuel shortage
Refuel Test signal from fuel gauge sender Test wiring between engine control unit and dash panel insert according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
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01
Readout on -V.A.G 1552 17733 Knock control Cyl. 1
OCTAVIA 1997
Rectifying fault Regulating limit reached
Inspecting knock sensors -G61- and -G66 - Chap. 28-1. Read measured value block, display group 026 Chap. 01-5 Eliminate abnormal engine running noises (loose ancillaries, bracket
or bolt bent)
Slacken knock sensors and then tighten again to 20 Nm Change type of fuel
17734 Knock control Cyl. 2 17735 Knock control Cyl. 3 17736 Knock control Cyl. 4 Regulating limit reached Regulating limit reached Regulating limit reached see fault code 17733
Note re fault codes 16505 and 16506: As soon as one of these faults is detected, the engine control unit uses a substitute value which is generated from the engine speed and the inducted air mass.
01-2 page 10
Self-diagnosis II
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OCTAVIA 1997
01
01-3
Self-diagnosis III
Fault table, fault codes 17743...18101

Readout on -V.A.G 155217743 Engine torque monitoring 2 17744 Engine torque monitoring 17748 Camshaft position/ crankshaft position sensor 17763 Ignition control cyl. 1 17764 Ignition control cyl. 1 17765 Ignition control cyl. 1 17766 Ignition control cyl. 2 17767 Ignition control cyl. 2 17768 Ignition control cyl. 2 17769 Ignition control cyl. 3 17770 Ignition control cyl. 3 17771 Ignition control cyl. 3 17772 Ignition control cyl. 4 17773 Ignition control cyl. 4 17774 Ignition control cyl. 4 17794 Control unit defective 17795 Control unit defective 17796 Control unit defective 17818 Tank ventilation valve -N80Short circuit to positive Regulating limit exceeded Regulating limit exceeded Incorrect assignment Rectifying fault
Inspect vacuum lines for tightness Inspect intake system for leaks Test coolant temperature sender Chapter 24-1 Test intake manifold temperature sender Chap. 24-1 Read measured value block, display group 002 Chapter 01-5 Inspect camshaft position sensor for tight installation
Open circuit Short circuit to positive Short circuit to earth Open circuit Short circuit to positive Short circuit to earth Open circuit Short circuit to positive Short circuit to earth Open circuit Short circuit to positive Short circuit to earth
Inspect ignition transformer Chapter 28-1
Test ignition coil Current Flow Diagrams, Electrical Fault Finding

and Fitting Locations
Replace engine control unit Chapter 24-4 Test earth cables according to current flow diagram Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations
control diagnosis
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01-3 page 1
01
Readout on -V.A.G 155217828 Secondary air injection valve -N11217829 Secondary air injection valve -N11217830 Secondary air injection valve -N11217832 Bank 1, secondary air system 17833 Tank ventilation valve -N8017834 Tank ventilation valve -N80-
OCTAVIA 1997
Rectifying fault Electrical fault in the circuit Short circuit to earth Short circuit to positive Leak detected
Test secondary air injection valve Chapter 01-4, Final control diagnosis
Short circuit to earth Open circuit
control diagnosis
control diagnosis
Open circuit 17841 Secondary air pump relay -J299Short circuit to 17842 Secondary air pump re- positive lay -J299Short circuit to 17843 Secondary air pump re- earth lay -J29917858 Secondary air system 17859 Secondary air system 17860 Secondary air system 17908 Fuel pump relay -J1717909 Fuel pump relay -J1717910 Fuel pump relay -J17Short circuit to positive Short circuit to earth Open circuit Electrical fault in the circuit Short circuit to earth Short circuit to positive
Test fuse 43 Test the relay or the secondary air pump Chapter 01-4, final control
diagnosis
Test fuel pump relay -J17- Current Flow Diagrams, Electrical Fault
17920 Short circuit to Valve for variable inpositive take manifold changeover -N15617921 2nd valve for variable intake manifold changeover -N26117922 2nd valve for variable intake manifold changeover -N261Short circuit to positive
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Short circuit to earth
01-3 page 2
Self-diagnosis III
Edition 01.04 S00.5128.53.20
OCTAVIA 1997 Readout on -V.A.G 1552-
2,0 l/85 kW Engine, Fuel Injection and Ignition System Rectifying fault
01
17923 Short circuit to Valve for variable inearth take manifold changeover -N15617924 Open circuit Valve for variable intake manifold changeover -N15617925 Main relay -J27117926 Main relay -J27117928 2nd valve for variable intake manifold changeover-N26117931 Crash signal from airbag CU 17947 Clutch pedal switch -F3617949 Fuel pump relay -17950 Angle sender for TV drive -G187-1) 17951 Angle sender for TV drive -G187-2) 17952 Angle sender for TV drive -G187-2) 17953 Throttle valve control 17966 Throttle valve drive -G186-1) 17967 Throttle valve control unit -J338-1) 17968 Maximum engine speed exceeded 17972 Throttle valve control unit -J33817973 Throttle valve control unit -J33817976 Throttle valve control unit -J338Undervoltage on basic setting Bottom limit not reached Mechanical fault Electrical fault in the circuit Short circuit to positive Open circuit
Test the power supply relay for Motronic -J271- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Implausible signal Implausible signal Open circuit Implausible signal Signal too low
Test airbag Body Work; Rep. Gr. 01 Test clutch pedal switch Read measured value block, display group 066 Chapter 01-7 Test fuel pump relay -J17- Current Flow Diagrams, Electrical Fault
Test throttle valve control unit Chapter 24-2 Test throttle valve control unit Chapter 24-2
Signal too high Malfunction Electrical fault in the circuit Incorrect basic setting
Adapt engine control unit to throttle valve control unit Chapter 24-4 Inspect engine for mechanical damage and erase fault memory
Chapter 01-1
Check engine speed sender -G28- Chapter 24-1 Inspect generator and battery voltage, charge battery Electrical
System; Rep. Gr. 27
Inspect throttle valve for damage and dirt Test throttle valve control unit Chapter 24-2
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01-3 page 3
01
Readout on -V.A.G 155217977 CCS switch -E4517978 Engine control unit inhibited 17987 Throttle valve control unit -J33817988 Throttle valve drive, bank 1 17990 Idling control Implausible signal
OCTAVIA 1997
Rectifying fault
Check cruise control system (CCS) in the measured value block, display group 066 Chapter 01-7 tem; Rep. Gr. 96.
Adapt engine control unit to electronic immobiliser Electrical SysAdaptation was not initiated Malfunction
Adapt engine control unit to throttle valve control unit Chapter 24-4 Test throttle valve control unit Chapter 24-2 Test throttle valve control unit Chapter 24-2 Inspect vacuum lines for tightness Test intake system for tightness Inspect exhaust system for tightness 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26
Adaption limit reached

control diagnosis 18010 Voltage supply tml. 30 18011 Control unit defective Voltage too low
Inspect generator and battery voltage, charge battery Electrical

System; Rep. Gr. 27
Diagrams, Electrical Fault Finding and Fitting Locations Electrical fault in the circuit
18014 Poor road info/engine spec. torque from ABS CU 18017 Crash disconnect activated 18018 Control unit defective
Read out fault memory of ABS control unit Chassis; Rep. Gr. 45 Inspect databus Chapter 24-5 Interrogate fault memory of airbag control unit and erase Body
Work; Rep. Gr. 01
Diagrams, Electrical Fault Finding and Fitting Locations Incorrectly coded Missing message from gearbox CU Signal too low
18020 Engine control unit 18034 Databus drive 18038 Sender for accelerator pedal position -G7918039 Sender for accelerator pedal position -G79-
Code engine control unit Chapter 24-4 Test databus cables Chapter 24-5 Test accelerator pedal position sender Chapter 24-2
Signal too high
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Self-diagnosis III
Edition 01.04 S00.5128.53.20
OCTAVIA 1997 Readout on -V.A.G 1552-
2,0 l/85 kW Engine, Fuel Injection and Ignition System Rectifying fault Signal too low
01
18041 Sender 2 for accelerator pedal position -G18518042 Sender 2 for accelerator pedal position -G18518044 Databus drive 18047 Sender 1/2 for accelerator pedal position -G79- + -G18518048 Control unit defective
Signal too high
Missing message from airbag CU Implausible signal
Inspect databus Chapter 24-5 Test accelerator pedal position sender Chapter 24-2
Diagrams, Electrical Fault Finding and Fitting Locations defective Missing message from ABS CU Missing message from combiinstrument Programming not ended implausible message from ABS CU implausible message from airbag-SG Open circuit
18056 Databus drive 18057 Databus drive 18058 Databus drive
Inspect databus Chapter 24-5 Inspect databus Chapter 24-5 Interrogate fault memories of all control units (automatic test sequence) Chap. 01-1
18089 Control unit programming 18090 Databus drive 18091 Databus drive 18099 Self-diagnosis fault lamp -K8318100 Self-diagnosis fault lamp -K8318101 Self-diagnosis fault lamp -K8319667 Exhaust gas - bank 1 probe 1 19722 Bank 1 - probe 1
1) 2)
Replace engine control unit Chapter 24-4 Inspect databus Chapter 24-5
Check self-diagnosis fault lamp -K83- Current Flow Diagrams,

Electrical Fault Finding and Fitting Locations
Short circuit to earth Short circuit to positive Heating feedback Internal resistance implausible


Throttle valve drive (electronic power control) -G186- is also known as throttle valve positioner (for intake manifold) -V60-. Angle sensor for throttle valve drive (electronic power control) -G187- is also known as throttle valve position sender -G127-.
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01
Note regarding fault code 17978:
OCTAVIA 1997
The immobilizer control unit is located in the dash panel insert and cannot be replaced individually. When attempting to start with a non-adapted key a static fault is stored in the memory. If a subsequent start attempt occurs with an adpated key the fault is changed to a sporadic fault.
01-3 page 6
Self-diagnosis III
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
01
01-4
Self-diagnosis IV
Actuator diagnosis
With the actuator diagnosis the following parts are activated in the sequence indicated: 12345Injector cyl. 1 -N30Injector cyl. 2 -N31Injector cyl. 3 -N32Injector cyl. 4 -N33Activated charcoal filter system solenoid valve 1 -N80-
For engines with engine code AZH 6 - Secondary air pump relay -J299For engines with engine code AQY 6 - Secondary air injection valve -N112 7 - Secondary air pump relay -J299-
For engines with engine code AZJ

1 - Activated charcoal filter system solenoid valve 1 -N802 - Secondary air pump relay -J2993 - Injector cyl. 1 -N304 - Injector cyl. 3 -N325 - Injector cyl. 4 -N336 - Injector cyl. 2 -N31Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
Fuses o.k.
Note The final control diagnosis takes place for the individual engine code according to the above-mentioned order. The actuator diagnosis can only be carried out when the engine is not running and the ignition is switched on. The final control diagnosis is interrupted if the engine is started or if an engine speed pulse is detected. During the actuator diagnosis the individual actuators remain activated until the next actuator is selected by pressing key . The actuators are tested acoustically or by touch.
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01-4 page 1
01
OCTAVIA 1997
Before repeating final control diagnosis without briefly running the engine in-between, switch the ignition off for about 2 seconds. The electric fuel delivery unit runs during the entire final control diagnosis. Final control diagnosis is aborted after 10 minutes.
Procedure
Connect vehicle system tester -V.A.G 1552-. Switch

ignition on and select address word 01 Engine electronics Chap. 01-1.
Enter the function 03 Final control diagnosis and

confirm entry using the Q key.
Actuate injectors -N30- to -N33-:

Readout on display: Note The fuel delivery unit must run and the fuel flow must be audible at the fuel pressure regulator. If the fuel delivery unit does not run, test actuation 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 20.
Actuator diagnosis Injector cyl. 1 N30 ->
Open throttle valve. After the idling speed switch

opens, the cylinder injector closes five times.
The next injector is operated by pressing the
button. (Procedure can also be performed without testing the relevant injector.)
Test all the injectors one after the other in this way.
If one of the injectors is not actuated (does not click):
Test injectors and cable connections for an open cir-
cuit, short circuit to earth and to positive Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Activating solenoid valve for activated charcoal filter -N80-:
Press
key. The activated charcoal filter solenoid
valve must continue clicking audibly until the next control element is actuated by pressing the key. The valve clicks, but there is nevertheless probably a fault (the valve does not open, or does not close):
Actuator diagnosis -> Activated charcoal filter solenoid valve N80
Detach hose from activated charcoal filter solenoid

valve.
Fit an auxiliary hose onto the free connection of the

valve.
Blow into this hose during final control diagnosis.

The valve must open and close. If the solenoid valve does not click:
01-4 page 2
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Edition 01.04 S00.5128.53.20
OCTAVIA 1997
01
Test activated charcoal filter solenoid valve -N80- and

cable connections for open circuit, short circuit to earth and to positive Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Actuate secondary air inlet valve -N112-:
Press
key. The secondary air inlet valve must con-
tinue clicking until the next control element is actuated by pressing the key. If the valve does not click:
Actuator diagnosis Secondary air inlet valve N112
->
Testing secondary air injection valve.

Actuate secondary air pump relay -J299-:
Press
key. The secondary air pump relay -J299- is
controlled by the motor for the secondary air pump. It continues running at intervals until the key is pressed. If the secondary air pump motor -V101 - does not run at intervals:
Actuator diagnosis Secondary air pump relay J299
->
Testing secondary air pump motor Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Enter function 06 End output and switch ignition off.

Note The ignition must be switched off after final control diagnosis is ended. If the ignition is not switched off before the engine is next started, the engine will not start as the injectors and the ignition transformer are not operated.
Readiness code
For engines with engine codes AQY, AZH, AZJ
Operation The readiness code is an 8-digit numerical code that provides information on the status of the emission-relevant diagnosis. Diagnoses in normal operation are performed at regular intervals. 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. If diagnosis of a system has been performed (e.g. of the secondary air system), the appropriate code number position is set from 1 to 0. Readiness code 00000000 means that the individual diagnoses have been successfully performed. Readiness Code is erased after the fault memory is erased or if the power supply is interrupted.
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01-4 page 3
01
Reading readiness code
OCTAVIA 1997
Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
Connect vehicle system tester -V.A.G 1552-, switch

ignition on and enter address word 01 Engine electronics Chapter 01-1.
Enter function 15 Readiness code and confirm the

entry with the Q key. The following readout must appear in the display after successfully completing all the diagnoses: Specified value: 00000000
Readiness code 00000000 - Test complete
Press key. Enter function 06 End output and switch ignition off.
One of the diagnoses has not been successfully performed, e.g.:
Readiness code 00101101 - Test not complete
Press key. Generate readiness code 01-4 page 4.

Meaning of the 8-digit numerical block of the readiness code
The readiness code is only generated when all display positions are at 0 1 2 3 4 5 6 7 0 0 0 0 0 0 0 8 0 Catalytic converter Catalytic converter heater (no diagnosis at present/always 0) Activated charcoal filter system (tank ventilation system) Secondary air system Air conditioning system (no diagnosis at present/always 0) Lambda probes Lambda probe heater (no diagnosis at present/always 0) Exhaust gas recirculation (not fitted/always 0) Diagnosis function
Generating readiness code

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OCTAVIA 1997
01
Test conditions
Vehicle stopped On vehicles with an automatic gearbox the selector lever must be in position P or N
All electrical components such as headlights and rear

window heater, must be switched off.
Intake air temperature less than 60 C measured value block 004, display field 4 Chapter 01-5 block 004, display field 3 Chapter 01-5
Coolant temperature at least 80 C measured value

Procedure
Connect vehicle system tester -V.A.G 1552-, switch

ignition on and enter address word 01 Engine electronics Chapter 01-1. Note It is essential to carry out the individual steps in the correct order, otherwise the readiness code cannot be successfully generated. 1. step: Interrogating fault memory Readout on display:
Vehicle system test Select function XX HELP
Enter function 02 Interrogate fault memory and confirm entry with Q key. The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
X No fault recognised!
Rectify the faults displayed by referring to the fault table Chapter 01-2, Chapter 01-3. If no fault is stored:
Press
key.
2. step: Erasing fault memory
Enter function 05 Erase fault memory and confirm

entry with the Q key. Note Readiness code is erased each time the fault memory is erased. Readout on display: Note If the ignition is switched off between Interrogating fault memory and Erasing fault memory, the fault memory is then not erased. 3. step: Adapting throttle valve control unit to engine control unit
Vehicle system test Select function XX
HELP
Vehicle system test Fault memory erased!
->
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01-4 page 5
01
group 060. For engines with engine code AQY
OCTAVIA 1997
Select function 04 Initiate basic setting and display

System in basic setting 60 xx x.x V Idling -> ADP runs
Display field 3:
Specified value: Idling For engines with engine codes AZH, AZJ
System in basic setting 60 xx % xx % 8 -> ADP runs
Display field 3:
Specified value: 0...8 Continued for all engines
Display field 4:
Specified value: ADP runs, ADP o.k.
End adjustment only after 30 seconds have passed by

pressing the
key.
If one of the above messages appears:
Check throttle valve control unit -J338-.

4. step: Diagnosis of secondary air injection system
Start engine and run in idle.

Note The engine must not be switched off during the entire period.
Select function 04 Initiate basic setting and display

group 077. After initiating diagnosis of engine control unit the message in display field 4 changes from Test OFF to Test ON. Read-out on the display for engines with engine code: AQY, AZH AZJ
System in basic setting 77 xxx.x C xx.x % System in basic setting 77 780/min x.x g/s x.x g/s
-> Test ON -> Test ON
Leave engine idling until the following readout appears in display field 4: Specification Syst. o.k. If the message is not displayed:
Interrogate fault memory Chapter 01-1.

If the message is displayed: 5. step: Diagnosis of activated charcoal filter system (tank vent system)
Enter display group 070.

After initiating diagnosis of engine control unit the message in display field 4 changes from Test OFF to Test ON.
Self-diagnosis IV Edition 01.04 S00.5128.53.20
01-4 page 6
OCTAVIA 1997
01
-> Test ON -> Test ON
Read-out on the display for engines with engine code: AQY AZH, AZJ
System in basic setting 70 xx.x % x.x % xx.x g/s System in basic setting 70 xx.x % - x.x % xx.x %
Leave engine idling until the following readout appears in display field 4: Specified value: TVV o.k. If this message is not displayed:

If this message is displayed:
key.
Press
6. step: Testing operating state of lambda control Lambda control can only be tested at a catalytic converter temperature of more than 352 C. To achieve this, engine speed must be increased for several minutes to 2800...3200 rpm. Read off the catalytic converter temperature in measured value block 034.
Select function 08 Read measured value block and

display group 034.
Set engine speed to 2800...3200 rpm until the catalytic converter temperature in display field 2 is more than 352C. Note This may take a few mlnutes.
Reading measured value block 34 3000 rpm 352 C xx.xx s
-> Text
Press C key. Enter display group 030. Check operating state of lambda control upstream of
catalytic converter (display field 1): Specified value: 111
Reading measured value block 111 110
30
->
Check operating state of lambda control downstream

of catalytic converter (display field 2): Specified value: 110 meaning 01-4 page 8 Note The first position in the 3-digit numerical block fluctuates initially between 0 and 1 (lambda probe heater OFF and ON). Bits in display field 2 are only set to value 1 once the lambda probe downstream of the catalytic converter is heated up. The catalytic converter temperature must be more than 352 C. The lambda control of lambda probe downstream of catalyst is not active without engine load and the third position in display field 2 indicates 0.
Edition 01.04 S00.5128.53.20
Self-diagnosis IV
01-4 page 7
01
OCTAVIA 1997
Meaning of 3-digit numerical block in display fields 1 and 2:
2 1
3 1 Lambda control active Lambda probe operational
Meaning if display position
Lambda probe heater switched on
If the specified values are not reached:

If the specified values are reached:
key.
Press
7. step: Diagnosis of lambda probe ageing (monitoring period)
Select function 04 Basic setting and display group

034. For engines with engine code AQY
Maintain engine speed at 2200...2800 rpm until message in display field 4 changes from Test OFF to Test ON. For engines with engine code AZH
System in basic setting 34 2800 rpm 352 C 2.2 s
-> Test ON
Press down the brake pedal. Engine speed is increased and the readout in display
field 4 switches from Test OFF to Test ON. For engines with engine code AZJ
System in basic setting 34 2300 rpm 352 C 1,78
-> 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. Continued for all engines Catalytic converter temperature in display field 2 must be at least 352 C. Note If the message does not change to Test ON, vary engine speed. For engines with engine code AQY
System in basic setting 34 2300 rpm 352 C 1.78
-> Test OFF
Check period in display field 3.

Specified value: max. 2.2 s For engines with engine codes AZH, AZJ
Check the dynamic factor in display field 3.

Specified value: min. 0.70 Continued for all engines
Maintain the increased engine speed.
01-4 page 8
Self-diagnosis IV
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
01
Specification in display field 4: "B1-S1 o.k." If the specified values are not reached:

If the specified values are reached: 8. step: Diagnosis of catalytic converter Note This diagnosis is only ended once the diagnosis of the lambda probe ageing has been successfully completed.
Enter display group 046.

For engines with engine codes AQY, AZH
Increase engine speed to 2800...3200 rpm until the readout in display field 4 changes from Test OFF to Test ON. Catalytic converter temperature in display field 2 must be at least 352 C.
System in basic setting 46 3000 rpm 352 C 0.55 -> Test OFF
Check amplitude ratio in display field 3.

Specified value: max. 0.55

Specification in display field 4: Cat B1 o.k. For engines with engine code AZJ
field 4 switches from Test OFF to Test ON. Catalytic converter temperature in display field 2 must be at least 352 C.
System in basic setting 46 2300 rpm 352 C 1.00 -> Test OFF

Specification in display field 4: Cat B1 o.k.
Check the effect of the catalytic converter in display

field 3: Specified value: min. 1.00 Continued for all engines Note The catalytic converter diagnosis only takes 100 seconds. If no result is shown within 150 seconds change the engine speed.
Enter function 06 End output and confirm entry with

Q key.

Edition 01.04 S00.5128.53.20
Self-diagnosis IV
01-4 page 9
01
9. step: Reading readiness code
OCTAVIA 1997
Read readiness code 01-4 page 4.
01-4 page 10
Self-diagnosis IV
Edition 01.04 S00.5128.53.20

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OCTAVIA 1997
01
01-6
Self-diagnosis VI
Reading measured value block, display groups 030 to 062

Display group 030 - lambda control
Engine idling Catalytic converter temperature at least 352 C (display group 034, display field 2)
Read measured value block 30 xxx 1 xxx 2 3 4 Display field Specification Analysis Readout on display
Status of lambda control downstream of catalytic converter1) Status of lambda control upstream of catalytic converter
1)
110 111
01-6 page 1 01-6 page 1
For engines with engine codes AQY, AZH, AZJ
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.
Meaning of 3-digit numerical block in display fields 1 and 2:
Meaning, if display positions = 1 Lambda control active Lambda probe operational Lambda probe heater switched on
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OCTAVIA 1997
Display group 031, lambda control - lambda values upstream of catalytic converter
Engine idling
Read measured value block 31 x.xxxx 1 x.xxxx 2 3 4 Display field Specification Lambda nominal value - Bank 1 Lambda actual value - Bank 1 0,99001,0100 0,99001,0100 Analysis Readout on display
Display group 032, lambda control - lambda learned values
Engine idling
Read measured value block 32 xx.x % 1 xx.x % 2 3 4 Display field Specification Lambda learned value at part load upstream of catalytic converter (multiplicative) Lambda learned value at idling speed upstream of catalytic converter (additive) -10,0...10,0 % -10,0...10,0 % Analysis 01-6 page 5 01-6 page 5 Readout on display
Note Re display fields 1 and 2: Low readouts indicate that the engine is running too rich and the lambda control therefore produces a leaner mixture. High readouts mean that the engine is running too lean and the lambda control therefore produces a richer mixture. If the control unit is dead all initialisation values are reset. Condition for part load learning. Coolant temperature at least 75 C, intake air temperature max. 90 C, driving mode.
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Self-diagnosis VI
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
01
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 multiplicative learned value is a percentage change in the injection period. This change is dependent on the basic injection period.
Display group 033, lambda control upstream of catalytic converter - lambda control values
Engine idling
Read measured value block 33 xx.x % 1 x.xxx V 2 3 4 Display field Specification Lambda probe voltage upstream of catalytic converter Lambda control before catalyst
1)
Readout on display
Analysis 01-6 page 5 01-6 page 5
0.00...10.00 V 1.40...1.60 V 1) -10,0...10,0 %
for engines with engine codes AZH, AZJ
Note Re display field 1: Readout must fluctuate around zero. If zero is always displayed, the lambda control has switched from closed-loop to open-loop control because of a fault in the lambda control. Interrogate fault memory Chapter 01-1. For engines with engine codes AEG, APK, AQY Note Voltage signal Mixture rich (low level of residual oxygen) is at approx. 0.7...1.0 V. Voltage signal Mixture lean (high level of residual oxygen) is at approx. 0.0...0.3 V. A voltage jump from 0.7...1.0 V to 0.0...0.3 V or vice versa takes place at the transition from rich to lean and vice versa (n = 1.0). In view of the steep voltage jump the lambda control is not able to maintain constant the ideal mixture composition which corresponds to n = 1.0. The control constantly fluctuates back and forward between the slightly too lean and slightly too rich states.
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The readout must in some cases be less than 0.3 V and in some cases more than 0.6 V. The readout below 0.45 V indicates a lean mixture while above 0.45 V indicates a rich mixture. At idling speed, the lambda probe voltage upstream of the catalytic converter must fluctuate between a rich and leaner mixture. The lambda probe voltage downstream of the catalytic converter should indicate a constant rich or lean mixture. If the voltage also fluctuates downstream of the catalytic converter, either the catalytic converter is faulty ( Read measured value block 046 01-6 page 10) or the probes have been wrongly connected (irregular engine running). Lambda control varies between -15...15 %. Voltage of the 4-pin lambda probe in Un 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 For engines with engine codes AZH, AZJ Note Re display field 2: Voltage signal Mixture rich (low level of residual oxygen) is at approx. 0.13...1.50 V Voltage signal Mixture rich (high level of residual oxygen) is at approx. 1.50...4.80 V
400 200 0 0,80 0,90 1,00 1,10 1,20
A24-0074
A
mV 800 600
01-6 page 4
Self-diagnosis VI
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
01
Analysis of display groups 032 and 033, display fields 1 and 2 - lambda learned values
Readout on -V.A.G 1552 low learned values
Rectifying fault
Disappears after driving on motorway or changing oil Test injectors Chapter 01-4, Final control diagnosis Test fuel pressure regulator and holding pressure Chap. 24-2 Test solenoid valve for activated charcoal filter Chapter 01-4, final control diagnosis
Test air mass meter Testing lambda probe heater upstream of catalytic converter
Chapter 24-3 high learned values
Test intake system for tightness Test injected quantity Chapter 24-2 Test air mass meter Test fuel pressure regulator and holding pressure Chap. 24-2 Test the exhaust manifold 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26 Chapter 24-3
Analysis of display group 033, display field 2 - lambda probe voltage upstream of catalytic converter
Display field: 1 constant 0.00...0.30 (0.00...1.50 V) 1) possibly constant 0.70...1.00 V (1.50...4.80 V)1) Rectifying fault
Testing the intake system for tightness (unmetered air) Inspect the spark plugs Inspection and Maintenance Test fuel pressure regulator and holding pressure Chap. 24-2 Test injectors Chapter 01-4, Final control diagnosis Test coolant temperature sender Chapter 24-1 Testing lambda probe heater upstream of catalytic converter Chapter 24-3 verter Chapter 24-3
Testing lambda probe and lambda control upstream of catalytic conconstant 1,00 V (greater than 4,80 V)1) constant 0.40...0.50 V (1.40..1.60 V)1) constant 0.00 V (less than 0.13 V)1)
1)

Chapter 24-3
Testing lambda probe and lambda control upstream of catalytic converter Chapter 24-3
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OCTAVIA 1997
Display group 034, lambda control - diagnosis of lambda probe upstream of catalytic converter (for engines with the engine codes AQY)
Vehicle stationary, engine running at fast idling Control unit in function 04 - initiate basic setting
System in basic setting 34 xxxx rpm 1 xxx.x C 2 x.x s 3 Text 4 Display field Results of a test of lambda probe ageing upstream of catalytic converter (Test OFF/Test ON/B1 S1 OK/ B1S1 not OK) Period of lambda probe upstream of catalytic converter Catalytic converter temperature Engine speed Specification B1 S1 OK Analysis Readout on display
max. 2.2 s min. 352 C 2200...2800 rpm
Note Re display field 3: The period indicates the time between two jumps (e.g. rich - lean - rich mixture) and is thus a measure of the status of the lambda probe ageing. If the specified time is exceeded, the following appears in display field 4: B1-S1 not OK
Display group 034, lambda control - diagnosis of lambda probe upstream of catalytic converter (for engines with the engine codes AZH, AZJ)
Control unit in function 04 - initiate basic setting AZH: Vehicle stationary, brake pedal depressed, engine running at fast idling AZJ: Vehicle stationary, brake and accelerator pedal depressed simultaneously, engine running at fast idling
System in basic setting 34 xxxx rpm 1 xxx.x C 2 xx.xx 3 Text 4 Display field Results of a test of lambda probe ageing upstream of catalytic converter (Test OFF/Test ON/B1 S1 OK/ B1 S1 not OK) dynamic factor Catalytic converter temperature Engine speed
1)
Readout on display Specification B1 S1 OK Analysis
do not observe min. 0.70 1) min. 352 C 1300...2600 rpm about 2300 rpm 1)
for engines with engine code AZJ
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Self-diagnosis VI
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
01
Note Re display field 3: The dynamic factor is the measure of the status of the lamda probe ageing. The lower the dynamic factor the more advanced the lamda probe ageing.
Display group 036, lambda control - operational readiness downstream of catalytic converter (for engines with engine codes AQY, AZJ)
AQY: Engine idling, engine at idling speed AZJ: Control unit in function 04 - initiate basic setting AZJ: Vehicle stationary, brake and accelerator pedal depressed simultaneously, engine running at fast idling
Read measured value block 36 x.xxx V 1 Text 2 3 4 Display field Specification Test lambda probe downstream of catalytic converter (Test OFF/Test ON/B1-S2 not OK) Lambda probe voltage downstream of catalytic converter B1 S2 o.k. 0.00...1.00 V Analysis 01-6 page 8 Readout on display
Display group 036, lambda control - operational readiness downstream of catalytic converter (for engines with engine codes AZH)
Vehicle stationary, brake pedal depressed, engine running at fast idling Control unit in function 04 - initiate basic setting
Read measured value block 36 x.xxx V 1 xxx.x C 2 xx.xx 3 Text 4 Display field Test lambda probe downstream of catalytic converter (Test OFF/Test ON/ B1-S2 not OK) No meaning Catalytic converter temperature Lambda probe voltage downstream of catalytic converter Specification B1 S2 o.k. Analysis Readout on display
min. 350 C 0.00...1.00 V
01-6 page 8
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OCTAVIA 1997
Analysis of display group 036, display field 1 - lambda probe voltage, lambda probe downstream of catalytic converter
Display field: 1 constant 0.00..0.30 V possibly constant 0.70...1.00 V
Rectifying fault
Testing the intake system for tightness (unmetered air) Inspect the spark plugs Inspection and Maintenance Test fuel pressure regulator and holding pressure Chap. 24-2 Test injectors Chapter 01-4, Final control diagnosis Test coolant temperature sender Chapter 24-1 Test tank ventilation Chapter 01-4, Final control diagnosis Test lambda probe heater downstream of catalytic converter Chapter 24-3 ic converter Chapter 24-3 Chapter 24-3
Testing lambda probe and lambda control downstream of catalytbetween 1.00 1.10 V 1) constant 0.40 ...0.50 V constant 0.00 V
1)
Test lambda probe heater downstream of catalytic converter Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-3
For engines with engine code AZH
Display group 037, lambda control - operational readiness downstream of catalytic converter (for engines with engine codes AEG, APK, AQY)
Engine idling Control unit in function 04 - initiate basic setting

System in basic setting 37 xxx.x % 1 x.xxx V 2 xxxx ms 3 Text 4 Display field Test lambda probe downstream of catalytic converter (B1 S2 OFF/B1 S2 ON/B1 S2 OK/B1 S2 not OK) Waiting time of lambda control upstream of catalytic converter Lambda probe voltage downstream of catalytic converter Engine load Specification B1 S2 o.k. Analysis Readout on display
-1200...1200 ms 0.00...1.00 V 15...35 %
01-6 page 8
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Self-diagnosis VI
Edition 01.04 S00.5128.53.20
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Note Re display field 3: If the readout rises above 200 ms, there is a leak in the exhaust system.
Display group 037, lambda control - operational readiness downstream of catalytic converter (for engines with engine codes AZH, AZJ)
Engine idling Control unit in function 04 - initiate basic setting

System in basic setting 37 xxx.x % 1 x.xxx V 2 3 Text 4 Display field Test lambda probe downstream of catalytic converter (Test ON / Test OFF, System OK / System not OK) Waiting time of lambda control upstream of catalytic converter Lambda probe voltage downstream of catalytic converter Engine load Specification System OK Analysis Readout on display x.xxx
0.00...1.00 V 10,0...25,0 %
01-6 page 8
Display group 041, lambda control - resistance of lambda probe heater
Engine idling
Read measured value block 41 xx.x Y 1 Text 2 xx.x Y 3 Text 4 Display field Lambda probe heating downstream of catalytic converter Resistance lambda probe heating downstream of catalytic converter Lambda probe heating upstream of catalytic converter Resistance of lambda probe heating upstream of catalytic converter
1)
Readout on display
Specification Htg dC.OFF Htg dC.ON 6,4...47,5 Y1) Htg.uC.OFF Htg.uC.ON 6,4...47,5 Y1)
Analysis
for engines with engine codes AEG, APK, AQY
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Note
OCTAVIA 1997
Depending on the operating state of the engine the lambda probe heaters are switched on or off, i.e. the readouts in display field 2 and 4 may show either Htg.u(d)C.ON or Htg.u(d)C.OFF.
Display group 046, lambda control - catalytic converter diagnosis (for engines with engine code AEG, APK, AQY, AZH)
Vehicle stationary, engine running at fast idling Control unit in function 04 - initiate basic setting
System in basic setting 46 xxxx rpm 1 xxx.x C 2 3 x.xx Text 4 Display field Test result of the catalytic conversion (Test OFF / Test ON / Cat B1 OK / Cat B1 not OK) Amplitude ratio Value of the catalytic converter conversion Catalytic converter temperature Engine speed
1)
Readout on display Specification Cat B1 OK Analysis
0,00...0,55 Ignore 1) min. 352.0 C 2800...3200 rpm
Display group 046, lambda control - catalytic converter diagnosis (for engines with engine code AZJ)
Vehicle stationary, brake and accelerator pedal depressed simultaneously, engine running at fast idling Control unit in function 04 - initiate basic setting
System in basic setting 46 xxxx rpm 1 xxx.x C 2 x.xx 3 Text 4 Display field Test result of the catalytic conversion (Test OFF / Test ON / Cat B1 OK / Cat B1 not OK) Effect of the catalytic converter Catalytic converter temperature Engine speed Specification Cat B1 OK Analysis Readout on display
min. 1.00 min. 352.0 C approx. 2300 rpm
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Self-diagnosis VI
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Note Re display field 3: The indicated value for the new catalytic converters should be above 5.00.
Display group 050, engine speed control - operating states
Engine idling
Read measured value block 50 xxxx rpm 1 xxxx rpm 2 Text 3 Text 4 Display field Operating condition air conditioning compressor ON/OFF Operating state of air conditioning Engine speed (idling speed - specified value) Engine speed (idling speed) Specification Compr. ON or Compr. OFF A/C High or A/C Low 780 rpm 840 rpm1) Analysis Readout on display
Chapter 01-5 display group 001, display field 1
1)
Note Re display field 2: What is displayed is the specification for the engine speed which is fixed by the engine control unit (internal computed value in control unit). In exceptional cases the idling speed can be adjusted. The idling speed when a gear is engaged is then changed automatically. Note Re display field 3: A/C High = air conditioning switched on to high heating or cooling capacity A/C Low = air conditioning not switched on Note Re display field 4: On vehicles not fitted with air conditioning the indication Compr. OFF is always displayed.
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OCTAVIA 1997
Display group 054, engine speed control - operating states
Engine idling Driving1)

Read measured value block 54 xxxx rpm 1 Text 2 xxx xxx.x %1) 3 xxx xxx.x %1) 4 Display field Throttle valve positioner angle Throttle valve angle Specification 0...100 %1) 0...6 0...100 %1) Idling 1) Analysis Chapter 01-5, display group 003, display field 3 Chapter 01-5, display group 022, display field 1 Readout on display
Operating state (idling, part load, full load, enrichment, overrun) Engine speed
1)
Display group 055, engine speed control - idling speed stabilisation
Engine idling
Read measured value block 55 xxxx rpm 1 x.xx g/s xx.xx %1) 2 x.xx g/s xx.xx %1) 3 xxxx xxxxx1) 4 Display field Operating conditions Initialisation value idling regulator Idling regulator Engine speed (idling speed) Specification xxxx xxxxx1) -1.50...1.50 g/s -10.0...10.0 %1) -2.00...2.00 g/s2) -10.0...10.0 %1) Analysis 01-6 page 13 Chap. 01-5, display group 001, display field 1 Readout on display
1) 2)
for engines with engine codes AZH, AZJ 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.
Note Re display field 3:1) 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.
01-6 page 12
Self-diagnosis VI
Edition 01.04 S00.5128.53.20
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01
Meaning of the numerical block display field 4, operating conditions

For engines with engine codes AEG, APK, AQY
3 1
4 1 Air conditioning compressor on
Meaning if display position Gear engaged, selector lever in 1/2/3/R/D (automatic gearbox) Air conditioning switched on No meaning
1 1
For engines with engine codes AZH, AZJ
4 1
5 1
Meaning if display position Air conditioning compressor on Gear engaged, selector lever in 1/2/3/R/D (automatic gearbox) Air conditioning switched on No meaning No meaning
1 1 1
Display group 056, engine speed control - idling speed stabilisation
Engine idling
Read measured value block 56 xxxx rpm 1 xxxx rpm 2 xx.xx g/s xx.x %1) 3 xxxx xxxxx1) 4 Display field Operating conditions Idling regulator Engine speed (idling speed - specified value) Engine speed (idling speed) Specification xxxx xxxxx1) -2.00...2.00 g/s -10.0...10.0 %1) 780 rpm 840 rpm2) Analysis 01-6 page 13 Chap. 01-5, display group 001, display field 1 Readout on display
1) 2)
for engines with engine codes AZH, AZJ For engines with engine code AZH
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Self-diagnosis VI
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OCTAVIA 1997
Display group 060 - adjustment of the throttle valve control unit
Ignition switched on, engine switched off Control unit in function 04 - initiate basic setting
System in basic setting 60 x xxx %1) 1 xx.x V xxx %1) 2 Text x1) 3 Text 4 Display field Adaption state (ADP runs, ADP o.k. or ADP ERROR) Engine operating state Learning steps counter1) Throttle valve positioner sender -G127 Throttle valve angle - Potentiometer 2 -G188-1) Throttle valve angle Throttle valve angle - Potentiometer 1 -G187-1)
1)
Readout on display
Specification ADP o.k. Idling 0...81) 0.0...5.0 V 97...3 %1) 0...6 3...97 %1)
Analysis Chapter 01-5, display group 003, display field 3
Note When display group 060 is selected in function 04 Initiate basic setting, the engine control unit is adapted to the throttle valve control unit. This adaption must be performed if another throttle valve control unit (or the complete engine), or another engine control unit, has been installed. Carry out the adaptation of throttle valve control unit with the ignition switched on. If the voltage supply has been interrupted (battery disconnected), it is also necessary to carry out adaption Chap. 24-4.
Display group 061 - engine speed control, E-gas (for engines with the engine codes AZH, AZJ)
Driving
Read measured value block 61 xxxx rpm 1 xx.xxx V 2 xxx.x % 3 xxxxx 4 Display field Operating conditions Actuate throttle valve drive -G186Supply voltage of the engine control unit Engine speed Specification xxxxx 0,0...100,0 % 13.50...14.50 V1) Analysis 01-6 page 13 Chapter 01-5, display group 022, display field 1 Readout on display
01-6 page 14
Self-diagnosis VI
Edition 01.04 S00.5128.53.20
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1)
Display group 062 - engine speed control, E-gas (for engines with the engine codes AZH, AZJ)
Ignition on
Read measured value block 62 xxx % 1 xxx % 2 xxx % 3 xxx % 4 Display field Sender 2 for accelerator pedal position -G185Sender 1 for accelerator pedal position -G79Throttle valve angle potentiometer -G188 Throttle valve angle potentiometer -G1871)
Readout on display
Specification 3...48 % 4...50 %1) 6...96 % 12...97 %1) 97...3 % 3...97 %
Analysis
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Self-diagnosis VI
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OCTAVIA 1997
01-6 page 16
Self-diagnosis VI
Edition 01.04 S00.5128.53.20

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OCTAVIA 1997
24
24 Fuel Formation, Injection

24-1 Repairing the injection system
General Instructions
Special instructions regarding ignition system Chapter 28-1. The engine control unit is equipped with a self-diagnosis system. Before commencing repairs and also for fault finding, first of all interrogate the fault memory. Also check the vacuum hoses and connections (unmetered air). Fuel lines must be secured only with spring strap clips. The use of clamp-type or screw-type clips is not allowed. Switch off the ignition before disconnecting and connecting the battery, as this may damage the 4AV control unit. Components marked with an * are checked by self-diagnosis Chapter 01-1. Components marked with ** can be checked by final control diagnosis Chap. 01-4. A minimum voltage of 11.5 V is required for perfect functioning of the electrical components. Do not use sealants containing silicone. Silicone particles are not combusted in the engine and damage the lambda probe. Certain inspections may cause the control unit to detect and store a fault. For this reason, after completing all the inspections and repairs, once again interrogate the fault memory, and erase it if necessary Chapter 01-1. Safety precautions 24-1 page 1. Cleanliless rules 24-1 page 2.
Safety instructions
WARNING! The fuel system is under pressure! Place a cloth around the connecting point before releasing hose connections or when opening the system. Then release pressure by carefully detaching. Observe the following points to prevent injury to persons and/or damage to the injection and ignition system: Do not touch or remove ignition leads with the engine running or at start speed. Do not disconnect or connect cables of the fuel injection and ignition system, also not cables of test equipment, unless the ignition is switched off.
Edition 01.04 S00.5128.53.20
Repairing the injection system
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OCTAVIA 1997
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 devices are operated from the passenger seat the passenger could be injured by the release of the passenger airbag in the event of an accident. If the engine must be operated at start speed without the engine starting:
Unplug 4-pin connector -1- from ignition transformer

-2-.
Remove fuse 28 for the fuel delivery unit.
Rules of cleanliness
5
8 9 10 11 38 39 40 41 42 43 44
12 13 14 15
16 17 18 19
20 21 22 23
Pay careful attention to the following five rules for cleanliness when working on the fuel supply or fuel injection system: Thoroughly clean the connection points and their surroundings before releasing. Place removed parts on a clean surface and cover. Do not use fuzzy cloths! Carefully cover or close opened components if the repair is not completed immediately. 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 using compressed air. Avoid moving the vehicle.
1 2 24 25 26 27 28 29 30
3 4 31 32 33 34 35 36 37
6 7
S97-0319
Individual components of system - Installation overview

For engines with engine identification characters AEG, APK, AQY, AZH
24-1 page 2
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
24
1 - Activated charcoal filter solenoid valve -N80-*/** s Activated charcoal filter 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 20 2 - Plug connection for lambda probe upstream of catalytic converter s for engines with engine identification characters AEG, APK, AQY - 4-pin s for engines with engine code AZH - 6-pin s driver side on right 3 - Plug connection for lambda probe downstream of catalytic converter s for engines with engine codes AQY, AZH s 4-pin s driver side on right 4 - Throttle valve control unit -J338 -* 5 - Engine control unit -J220-* s below the water box cover 6 - Combination valve s for engines with engine codes AQY, AZH 7 - Sender for coolant temperature -G62-* s resistances Fig. 1 in 24-1 page 10 8 - Secondary air injection valve -N112 -*/** s only engines with engine codes AQY, AZH 07.2000 s valve internal resistance 25...45 Y s Secondary air pump 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26 9 - Relay carrier s only engines with engine codes AQY, AZH s the secondary air pump relay is also located here -J299s the Motronic current supply relay is also located here -J27110 - Air mass meter -G70-* with intake air temperature sender -G42-* 11 - Injectors -N30-...-N33-*/** s item 8 in 24-1 page 9 12 - Secondary air pump -V101s only engines with engine codes AQY, AZH s Secondary air pump 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26 13 - Ignition transformer * s with power output stage -N122s with ignition coils -N-, -N128s inspect Chapter 28-1 14 - Knock sensor 2 -G66-* 15 - Engine speed sender -G28 -* s inductive pickup s Fitting location: under the oil filter in the cylinder block
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OCTAVIA 1997
s item 17 in 24-1 page 7 16 - 3-pin plug connection s for the engine speed sender -G28- grey 17 - Knock sensor 1 -G61-* 18 - Fuel pressure regulator 19 - Camshaft position sensor -G40 -* s inspect Chapter 28-1
For engines with engine code AZJ 1 - Activated charcoal filter solenoid valve -N80-*/** s Activated charcoal filter 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 20 2 - Return-flow line s secure with spring strap clip 3 - Feed line s secure with spring strap clip 4 - Camshaft position sensor -G40-* 5 - Valve for variable intake manifold changeover -N1566 - Top part of intake manifold s disassembling and assembling 24-1 page 10 7 - Bottom part of intake manifold s disassembling and assembling 24-1 page 8 8 - 81-pin plug connection s insert and remove plug when the ignition is switched off s unlock for removing 9 - Engine control unit -J220-* s below the water box cover 10 - 40-pin plug connection s insert and remove plug when the ignition is switched off s unlock for removing 11 - Throttle valve control unit -J338 -* 12 - Combination valve s Secondary air pump 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26 13 - Relay carrier s the secondary air pump relay -J299- and the Motronic current supply relay -J271- is also located here 14 - Sender for coolant temperature -G62-* s resistances Fig. 1 in 24-1 page 10 s with coolant temperature gauge sensor -G2s before removing, reduce pressure in cooling system if necessary 15 - Air mass meter -G70-* with intake air temperature sender -G42-* 16 - Air filter
24-1 page 4
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s disassembling and assembling 24-1 page 8 17 - Main fuse box 18 - ignition coil with power output stage (- N70-, -N127-, -N291-, -N292-) 19 - Engine speed sender -G28 -* s inductive pickup s Fitting location: under the oil filter in the cylinder block s item 17 in 24-1 page 7 20 - Secondary air pump -V101s Secondary air pump 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 26 21 - Injectors -N30-...-N33-*/** s item 8 in 24-1 page 9 s with air ring 22 - Knock sensor 2 -G66-* 23 - Knock sensor 1 -G61-* 24 - Valve 2 for variable intake manifold changeover -N26125 - Plug connection for lambda probe downstream of catalytic converter s 4-pin s driver side on right 26 - Lambda probe after catalyst -G130 -*, 50 Nm s Fitting location: in exhaust pipe downstream of catalytic converter s coat only thread with hot bolt paste G052 112 A3; the hot bolt paste must not get into the slots of the probe body s Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-3 27 - Plug connection for lambda probe upstream of catalytic converter s 6-pin s driver side on right 28 - Lambda probe upstream of catalytic converter -G39-*, 50 Nm s Fitting location: in the exhaust manifold s coat only thread with hot bolt paste G052 112 A3; the hot bolt paste must not get into the slots of the probe body s Testing lambda probe and lambda control upstream of catalytic converter Chapter 24-3 s Test lambda probe ageing upstream of catalytic converter Chapter 24-3 29 - Fuel pressure regulator s Test fuel pressure regulator and holding pressure Chap. 24-2
Removing and installing parts of the injection system

Edition 01.04 S00.5128.53.20
24-1 page 5
24
1 - Top part of intake manifold 2 - from activated charcoal filter solenoid valve -N80s Activated charcoal filter 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 20 3 - Plug connection s for engines with engine identification characters AEG, APK, AQY - 52-pin s for engines with engine code AZH - 81-pin s insert and remove plug when the ignition is switched off s unlock for removing
OCTAVIA 1997
2 28
4 5 6 7
27 8 9 25 26 10 8 8 14 16 17 8 15 11
4 - Engine control unit -J220-* s Fitting location: in plenum chamber s testing voltage supply Chapter 24-4 24 s procedure if voltage interrupted Chapter 24-4 23 22 s replacing Chapter 24-4 5 - Plug connection 21 19 s for engines with engine identification characters AEG, APK, AQY - 28-pin s for engines with engine code 18 AZH - 40-pin s insert and remove plug when the ignition is switched off 20 s unlock for removing 6 - Secondary air injection valve -N112 s only engines with engine codes AQY, AZH 07.2000 7 - Air filter s disassembling and assembling 24-1 page 8 8 - 10 Nm 9 - to air guide pipe s to injectors with air ring 10 - Air intake hose s only engines with engine codes AQY, AZH s to secondary air pump -V10111 - 6 Nm 12 - Connector s 4-pin s to coolant temperature sender -G62-
12 13
S24-0421
13 - Sender for coolant temperature -G62-* s with coolant temperature gauge sensor -G2s before removing, reduce pressure in cooling system if necessary s resistances Fig. 1 in 24-1 page 10 14 - Retaining clip s check tightness 15 - 3-pin connector s grey
24-1 page 6
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s for engine speed sender -G28 16 - O-ring s replace if damaged 17 - Engine speed sender -G28 -* s resistance between contacts 480...1000 Y 18 - Lambda probe after catalyst -G130 -*, 50 Nm s Fitting location: in exhaust pipe downstream of catalytic converter s only engines with engine codes AQY, AZH s Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-3 19 - Plug connection for lambda probe downstream of catalytic converter s only engines with engine codes AQY, AZH s 4-pin s Brown s for lambda probe downstream of catalytic converter -G130- and lambda probe heater downstream of catalytic converter -Z29s Fitting location item 3 in 24-1 page 3 20 - Lambda probe upstream of catalytic converter -G39-*, 50 Nm s Fitting location: in the exhaust manifold s coat only thread with hot bolt paste G052 112 A3; the hot bolt paste must not get into the slots of the probe body s Power supply of probe heating via fuel pump relay -J17s Testing lambda probe and lambda control upstream of catalytic converter Chapter 24-3 s Test lambda probe ageing upstream of catalytic converter Chapter 24-3 21 - Plug connection for lambda probe upstream of catalytic converter s for engines with engine identification characters AEG, APK, AQY - 4-pin s for engines with engine code AZH - 6-pin s black s for lambda probe -G39- upstream of catalytic converter and lambda probe heater upstream of catalytic converter -Z19s Fitting location item 2 in 24-1 page 3 22 - Bottom part of intake manifold s disassembling and assembling 24-1 page 8 23 - Fuel rail with injection valves s disassemble and assemble bottom part of intake manifold 24-1 page 8 24 - Fuel return-flow line s blue s secure with spring strap clamps s Check fitting position s to fuel delivery unit in fuel tank 2.0 l/85 kW Engine, Mechanical Components; Rep. Gr. 20 25 - Fuel feed line s black s from fuel filter 2.0 l/85 Engine, Mechanical Components; Rep. Gr. 20 26 - Gasket s replace if damaged s Check fitting position 27 - To crankcase vent valve 28 - Air intake hose
Edition 01.04 S00.5128.53.20
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OCTAVIA 1997
Disassembling and assembling the air filter

1 - Air mass meter -G70-* with intake air temperature sender -G42-* s -G42- resistances Fig. 1 in 24-1 page 10 2 - Gasket ring s replace if damaged 3 - Air filter top part 4 - 6 Nm 5 - Air deflector s in air filter top part 6 - Filter insert 7 - 10 Nm 8 - Air filter bottom part 9 - Air deflector 10 - Air intake hose s For engines with engine identification characters AQY, AZH, AZJ s to secondary air pump 11 - 6 Nm
1 11
3 4 5
10
6 7 8 9
N24-0948
Disassembling and assembling bottom part of intake manifold

24-1 page 8
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
24
1 - Fuel pressure regulator s Test fuel pressure regulator and holding pressure Chap. 24-2 2 - Vacuum hose s to top part of the intake manifold 3 - Cable rail s for connector for injection valves -N30 -...-N334 - Bottom part of intake manifold 5 - 10 Nm 6 - O-ring s replace s before fitting moisten lightly with clean engine oil 7 - To intake hose 8 - Injector -N30-...-N33-*/** s Air flushing s resistance 14.0...17.0 Y (at 20 C) 9 - Retaining clip s check tightness 10 - Fuel distributor 11 - Fuel return-flow line 12 - Fuel feed line 13 - Air guide pipe s to air flushing of the injector
11 12 13 9 6
7 6 4
9 10
5
S24-0308
Edition 01.04 S00.5128.53.20
24-1 page 9
24
1 - Fuel rail with injection valves 2 - Vacuum hose s to top part of the intake manifold 3 - Cable rail 4 - O-ring s replace if damaged 5 - Bottom part of intake manifold s with variable intake manifold changeover 6 - to the vacuum setting element s at the rear side of the intake manifold - lower part 7 - 3 Nm 8 - Valve 2 for variable intake manifold changeover -N2619 - 5 Nm 10 - Washer 11 - 25 Nm 12 - from the top part of the intake manifold 13 - Gasket ring s replace
OCTAVIA 1997
Fig. 1:
resistances
B
900 800
Chart applies to: Coolant temperature sender -G62 - at contacts 3 + 4. Intake air temperature sender -G42- at contacts 1 + 3. The diagram is divided into two temperature ranges: A - from 0 to 50C B - from 50 to 105C Read out examples: For a temperature of 30C the specification is 1500...2000 Y For a temperature of 80C the specification is 275...375 Y
7000 6000 5000 4000 3000 2000 1000 0 10 20 30 40 50 60 70 80 90 100 C
700 600 500 400 300 200 100
N24-0157
Disassembling and assembling top part of intake manifold

24-1 page 10
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OCTAVIA 1997
24
1 - 8 Nm 2 - Throttle valve control unit -J338 -* 3 - Gasket ring s replace if damaged 4 - Pressure relief valve s protects intake manifold from damage if excess pressure exists 5 - Vacuum hose s from the suction hose 6 - To the brake servo unit 7 - 5 Nm 8 - Top part of intake manifold s with variable intake manifold changeover 9 - Body-bound rivet 10 - Vacuum hose s from the fuel pressure regulator 11 - to the vacuum setting element s on the underside of the upper part of the intake manifold 12 - to the T union 13 - Valve for variable intake manifold changeover -N15614 - 8 Nm 15 - Rubber bush 16 - Heat shield with intake manifold cover
Disassembling and assembling fuel distributor with injectors

Edition 01.04 S00.5128.53.20
24-1 page 11
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OCTAVIA 1997
1 - Retaining clip s check for firm seating 2 - Connection return-flow line s blue or marked in blue s secure with spring strap clip s check for firm seating s to fuel delivery unit in fuel tank 3 - Connection feed line s black with a white marking s secure with spring strap clip s check for firm seating s from fuel filter 4 - Fuel distributor 5 - Air guide pipe 6 - To intake hose 7 - Air guide hose s to air flushing of the injector 8 - Retaining clip s check tight connection of injectors in fuel rail 9 - Injector (-N30-...-N33-). s Air flushing s resistance 14.0...17.0 Y (at 20 C) 10 - O-ring s replace s before fitting moisten lightly with clean engine oil 11 - 8 Nm 12 - O-ring s replace 13 - Vacuum hose s to top part of the intake manifold 14 - Fuel pressure regulator s Test fuel pressure regulator and holding pressure Chap. 24-2
24-1 page 12
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OCTAVIA 1997
24
24-2
Testing components
Testing cables with test box -V.A.G 1598/ 22- or -V.A.G 1598/31Special tools, test and measuring equipment and auxiliary items required Test box -V.A.G 1598/22- or - V.A.G 1598/31Note Use adapter cables from adapter cable set for connecting the test equipment to the test box. The contact numbers of the connector of the engine control unit and the socket numbers of the test box agree.
Procedure
Switch off ignition. Unscrew windscreen wipers and cooling water tank
cover Body Work; Rep. Gr. 66. control unit connectors.
Release the connector catches and unplug the engine
Connect test box -V.A.G 1598/22- to connector of wiring loom.
V.A.G 1598/22
Perform test as described in the relevant repair sequences.
V.A.G 1598/22
S24-0400
Connect test box -V.A.G 1598/31- to connector of wiring loom. The earth clip of the test box must be connected to the negative battery terminal.
Whether the engine control unit remains connected to

the test box or not, is described in the relevant test procedures.
Testing throttle valve control unit -J338V.A.G 1598/31

Note If the throttle valve control unit is replaced, it is then essential to adapt this new control unit to the engine control unit Chapter 24-4. Special tools, test and measuring equipment and auxiliary items required Handheld multimeter, e.g. -V.A.G 1526 A oder BMeasuring tool set, e.g. -V.A.G 1594 A, B oder C-
N24-0943
Edition 01.04 S00.5128.53.20
Testing components
24-2 page 1
24
Test conditions
OCTAVIA 1997
Throttle valve must be in the idling position. Throttle cable must be correctly set, inspecting 2.0
l/85 kW Engine, Mechanical Components; Rep. Gr. 20
On vehicles with an automatic gearbox the selector lever must be in position P or N.
If vehicle is equipped with air conditioning, this must

be switched off.
If the vehicle is equipped with cruise control, it must be

correctly set.
Testing throttle valve drive -V60Test sequence
Unplug connector from throttle valve control unit. Measure resistance of throttle valve positioner between the following contacts: For engines with engine codes AEG, APK, AQY Models with CCS: Contact 7 + 8 Models without CCS: Contact 1 + 2 For engines with engine codes AZH, AZJ Contact 3 + 5 Specified value: 1...5 Y If the specified value is reached:
I
3 5
1 3
II
Test voltage supply and cables to throttle valve control

unit Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
If the specified value is not reached:
Replace throttle valve control unit -J338-. Adapt engine control unit to throttle valve control unit
Chapter 24-4.
S24-0491
Testing accelerator pedal position sender

Special tools, test and measuring equipment and auxiliary items required Handheld multimeter, e.g. -V.A.G 1526 A oder BMeasuring tool set, e.g. -V.A.G 1594 A, B oder C-
Operation
The two accelerator pedal position senders -G79- and -G185- are located at the accelerator pedal and pass on
24-2 page 2
Testing components
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
24
the driver input to the engine control unit completely independently of each other (when accelerator is depressed). Both senders are located in a housing.
Test condition
Battery voltage at least 11.5 V.

Testing voltage supply and cables to engine control unit
Remove bottom part of dash panel on left Body

Work; Rep. Gr. 70.
Separate the 6-pin plug connection of the accelerator

pedal position sender.
Switch on ignition. Connect the multimeter for voltage measurement to

the following contacts of the connector: Contact 1 + earth Contact 1 + 5 Contact 2 + earth Contact 2 + 3 Specified value: min. 4.5 V
If the specified values are not reached: Test cables to accelerator pedal position sender for
open circuit or short circuit to earth or to positive Current Flow Diagrams, Electrical Fault Finding and Fitting Locations If the lines are not found to be faulty:
Replace accelerator pedal position sender.
Testing injected quantity and injectors for leaks

Special tools, test and measuring equipment and auxiliary items required Remote control, e.g. -V.A.G 1348/3AAdapter, e.g. -V.A.G 1348/3-2Measuring glasses, e.g. -V.A.G 1602Measuring tool set, e.g. -V.A.G 1594 A, B oder C-
Test condition
The fuel pressure must be OK, test 24-2 page 5 Fuel pump relay -J17- OK Fuel temperature 15...20C. Ambient temperature. The fuel used for testing must conform to the valid standards.
Edition 01.04 S00.5128.53.20
Testing components
24-2 page 3
24
Test sequence
OCTAVIA 1997
Remove the fuel rail with injection valves from the intake manifold (the fuel hoses remain connected) Chapter 24-1.
Detach air guide pipe for air flushing of the injectors Detach vacuum hose from fuel pressure regulator. Lift fuel rail together with injectors off intake manifold
and support.
Check tightness
Connect adapter cable with adapter -V.A.G 1348/3-2to fuse socket no. 28 -arrow-.
Hold the injectors in the measuring glasses. Connect alligator clip to battery positive (+).
The fuel delivery unit must start running.
Test the tightness of the injectors (visual inspection).

With the fuel delivery unit running, only 1 to 2 drops a minute should drip out at each valve. If the fuel loss is greater than this:
Switch off the voltage supply of the fuel delivery unit

and replace the leaking injection valve. Note Always fit new seals.
Testing fuel injected quantity
Insert the injectors to be tested in the measuring

glasses.
Connect one contact of injector to the battery earth. Connect the second contact of the injector to the remote control.
V.A.G 1348/3-2
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.
Operate remote control for 30 seconds. Repeat test at the other injectors. Always use a new
measuring glass.
Once all the injectors have been driven, position the

graduated measuring glasses on an even base.
V.A.G 1348/3A
A24-0079
Switch off voltage supply of fuel delivery unit. Compare the individual quantities of fuel injected.
Specified value: 88...98 ml per valve.
24-2 page 4
Testing components
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
24
If the measurement obtained for one or several injectors is not within the specification:
Replace the faulty injector.

Note When testing the injection rate also check the jet formation. The jet must be the same for all valves. 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.
Testing fuel pressure regulator and holding pressure

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 1318Adapter, e.g. -V.A.G 1318/10Adapter, e.g. -V.A.G 1318/11Adapter, e.g. -V.A.G 1318/16-
Test condition
Delivery rate of fuel delivery unit o.k., testing 2.0 l/

85 kW Engine, Mechanical Components; Rep. Gr. 20
Test sequence
WARNING! The fuel system is under pressure! Place a cloth around the connecting point before releasing hose connections or when opening the system. Then release pressure by carefully detaching.
Pull off the fuel feed line -1- and gather residual fuel in
a cloth.
1
N24-0795
Edition 01.04 S00.5128.53.20
Testing components
24-2 page 5
24
OCTAVIA 1997
Connect up the pressure measuring device. Open shut-off cock of the pressure measuring device.
Lever points in direction of flow.
Start engine and run in idle. Measure fuel pressure.

Specified value: approx. 0.25 MPa (2.5 bar) If the specified value is reached:
Detach vacuum hose -1- from connection -2-.

The fuel pressure must rise to approx. 0.3 MPa (3.0 bar).
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 bar):
2 1
N24-0797
Start engine and run in idle. After the pressure has been built up, switch ignition
off. At the same time close the shut-off cock of the pressure measuring device (lever at right angles to direction of flow of fuel -arrow-).
Observe pressure drop at gauge.

If the pressure again drops:
Test non-return valve of fuel delivery unit 2.0 l/85

kW Engine, Mechanical Components; Rep. Gr. 20 If the pressure does not drop:
24-2 page 6
Testing components
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
24
Open shut-off cock of pressure measuring device

-V.A.G 1318- (lever in direction of flow of fuel).
Start engine and run in idle. After the pressure has been built up, switch ignition
off. Press together the return-flow hose at the same time. If the pressure does not drop:
Replace fuel pressure regulator.

If the pressure drops:
Inspect connections, O-rings, injectors and fuel distributor for leaks.
Inspect pressure measuring device for leaks.

Note Before taking off the pressure measuring device, place cleaning cloths around the loose hoses of the feed line.
Edition 01.04 S00.5128.53.20
Testing components
24-2 page 7
24
OCTAVIA 1997
24-2 page 8
Testing components
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
24
24-3
Check for proper operation
Testing lambda probe -G39- and lambda control upstream of catalytic converter
Test conditions
Fuse 43 must be o.k. Battery voltage at least 11.5 V. The fuel pump relay must be OK.
Test sequence
8 5 1 2 24 25 26 27 28 3 4 31 32 33 34 35 36 37 6 7 9 10 11 38 39 40 41 42 43 44
12 13 14 15
16 17 18 19
20 21 22 23
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1. For engines with the engine identification characters AEG, APK
29 30
Check display groups 030, 031, 032, 033 and 041

Chapter 01-6. For engines with engine codes AQY, AZH, AZJ
S97-0319
Check display groups 030, 031, 032, 033, 034, 036,

041 and 107 Chapter 01-6 and 01-7. If the specified values are not reached: For engines with engine codes AEG, APK, AQY
Test resistance of heating element between the contacts 1 + 2. For engines with engine codes AZH, AZJ
Test resistance of heating element between the contacts 3 + 4. Continued for all engines Note At ambient temperature the resistance of the heating element should be approx. 1...5 Y. The resistance increases considerably even if the temperature rises only slightly.
Test voltage supply of heater and cables to - Z19-.

If the specified resistance is reached and the voltage supply for heater and cables to -Z19- is o.k.
Start engine.
Edition 01.04 S00.5128.53.20
24-3 page 1
24
OCTAVIA 1997
Use handheld multimeter to measure voltage between

the contacts 3 and 4 of connector at the wiring loom. For engines with engine codes AZH, AZJ
4
the contacts 1 and 5 of connector -2- at the wiring loom. Continued for all engines Specified value: 0.40...0.50 V.
M24-0010
6 4 2
Switch off ignition.

2 4 6
Replace lambda probe -G39-.

5 3 1
1 3 5
Test cables between engine control unit and connector of lambda probe Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
S24-0456
If the cable is not found to be faulty:
Replace engine control unit Chapter 24-4.
Testing lambda probe ageing upstream of catalytic converter -G39For engines with engine codes AQY, AZH, AZJ
Test condition
Coolant temperature at least 80C measured value

block 004, display field 3 Chapter 01-5.
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
24-3 page 2
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
24
Select function 04 System in basic setting and display group 034. For engines with engine code AQY
Increase and maintain engine speed at 2200...2800

rpm until the readout in display field 4 changes from Test OFF to Test ON. For engines with engine code AZH
System in basic setting 34 2800 rpm 355 C 2.20 s
-> Test ON
Press down the brake pedal. Engine speed is increased and the readout in display
field 4 switches from Test OFF to Test ON. For engines with engine code AZJ
34 -> Test OFF
field 4 switches from Test OFF to Test ON. Continued for all engines Note This may take a few minutes. Catalytic converter temperature in display field 2 must be at least 352 C. For engines with engine code AQY
-> Test OFF
Check period in display field 3:

Specified value: max. 2.20 s
Maintain engine speed at 2200...2800 rpm until the readout in display field 4 shows B1 S1 OK. For engines with engine codes AZH, AZJ
Check the dynamic factor in display field 3.

Specified value: min. 0.70
Maintain the increased engine speed until the readout

in display field 4 shows B1 S1 OK. Continued for all engines If the specified values are not reached:
Conduct a test drive in order to eliminate any residues

on the lambda probe and repeat the test. Pay attention to safety precautions during the test drive Chap. 24-1. If the specified value is again not reached:
Replace lambda probe upstream of the catalyst

-G39-.
Edition 01.04 S00.5128.53.20
24-3 page 3
24
OCTAVIA 1997
Testing lambda probe -G130- and lambda control downstream of catalytic converter
Only engines with engine identification characters AQY, AZH, AZJ
Test conditions
Fuse 43 must be o.k. Battery voltage at least 11.5 V. The fuel pump relay must be OK. Coolant temperature at least 80C measured value block 004, display field 3 Chapter 01-5.
1 2 24 25 3 4 31 32 33 34 35 36 37 5 6 7 8 9 10 11 38 39 40 41 42 43 44 12 13 14 15 16 17 18 19 20 21 22 23
Test sequence
26 27 28 29 30
Check display groups 030, 031, 036, 037 and 041

Chapter 01-6. If the specified values are not reached:
Test resistance of heating element between the contacts 1 + 2, voltage supply for heater and cables to -Z29- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Note At ambient temperature the resistance of the heating element should be approx. 1...5 Y. The resistance increases considerably even if the temperature rises only slightly. If the specified resistance is reached and voltage supply and cables to -Z29- are o.k.
S97-0319

the contacts 3 and 4 of connector at the wiring loom.
Start engine.
Specified value: 0.40...0.50 V
Switch off ignition.

If the specified value is reached:
Replace lambda probe after catalyst -G130-.

If the specified value is not reached:
Test cables to lambda probe -G130- Current Flow

Diagrams, Electrical Fault Finding and Fitting Locations. If the cable is not found to be faulty:
M24-0013
24-3 page 4
Edition 01.04 S00.5128.53.20
OCTAVIA 1997
24
Replace engine control unit Chapter 24-4.
Edition 01.04 S00.5128.53.20
24-3 page 5
24
OCTAVIA 1997
24-3 page 6
Edition 01.04 S00.5128.53.20

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Manual Skoda Octavia 2.0 85kW AEG APK AQY AZH AZJ

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2,0 l/85 kW Engine, Fuel Injection and Ignition System

List of Supplements to Workshop Manual

Edition 02.00 03.01 04.02 01.04

Article Number S00.5128.50.20 S00.5128.51.20 S00.5128.52.20 S00.5128.53.20

Edition 01.04 S00.5128.53.20

2,0 l/85 kW Engine, Fuel Injection and Ignition System

Edition 01.04 S00.5128.53.20

2,0 l/85 kW Engine, Fuel Injection and Ignition System

24 Fuel Formation, Injection

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Edition 01.04 S00.5128.53.20

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