Manual Skoda Octavia 1,9 66kW

Service
Workshop Manual OCTAVIA

1.9-ltr. / 66 kW (TDI) Engine Fuel Injection and Glow Plug System
Service Department. Technical Information

S00.5111.50.20 Edition 08.96
The Workshop Manual is intended only for use within the KODA Organisation; it is not permitted to pass it on to third parties. 1996 KODA, automobilov a.s.
Printed in Czech Republic
Service
List of Supplements to Workshop Manual OCTAVIA
Edition: 01.04
1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Replaces List of Supplements - Edition: 09.03
Supplement
Edition 05.97 03.98 02.99 12.00 09.03 01.04 08.96
Subject
Supplement to Basic Edition Modifications for Vehicles 08.97 Modification of Fault Code Modifications for Vehicles 08.00 Supplement to Repair Group 01 and 23 Supplement to Repair Group 01 and 23 Basic Edition of Workshop Manual
Article Number S00.5111.51.20 S00.5111.52.20 S00.5111.53.20 S00.5111.54.20 S00.5111.55.20 S00.5111.56.20 S00.5111.50.20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Contents next page.
The Service Manual is intended only for use within the koda Organisation; it is not permitted to pass it on to third persons. 2004 KODA AUTO a. s.
Printed in CR S00.5111.56.20
OCTAVIA
01 Self-Diagnosis
Contents
Service
Page
Measured value blocks ............................................................................................................... - Reading measured value block ................................................................................................ - Display nominal values for general vehicle inspection ............................................................. - Display nominal values for injection pump ............................................................................... - Display nominal values for engine idling .................................................................................. - Display nominal values for exhaust gas recirculation .............................................................. - Display nominal values for temperature sensor ....................................................................... - Display nominal values for automotive power .......................................................................... - Display nominal values for charge pressure control ................................................................
Readiness code ........................................................................................................................... - Reading readiness code ........................................................................................................... - Generate readiness code .........................................................................................................
Actuator diagnosis ...................................................................................................................... - Performing actuator diagnosis ................................................................................................. - Basic setting ............................................................................................................................. - Coding control unit ...................................................................................................................
Self-Diagnosis .............................................................................................................................. - Properties of the self-diagnosis ................................................................................................ - Technical data of self-diagnosis ............................................................................................... - Connecting tester V.A.G 1552 and select engine electronics control unit ................................ - Interrogating and erasing fault memory .................................................................................... - Fault table .................................................................................................................................
01-18 01-18 01-21 01-23
01-1 01-1 01-1 01-2 01-5 01-8
01-24 01-24 01-26
01-28.2 01-28.2 01-29 01-38 01-46 01-49 01-51 01-52 01-58
23
Fuel Formation/Injection
Servicing a diesel direct fuel injection system ......................................................................... - Safety measures ...................................................................................................................... - Rules for cleanliness ................................................................................................................ - Overview of fitting locations 07.97 ....................................................................................... - Overview of fitting locations 08.97 07.00 ............................................................................. - Overview of fitting locations 08.00 ....................................................................................... - Assembly overview of injection pump ...................................................................................... - Assembly overview of fuel filter ................................................................................................ - Assembly overview of throttle mechanism ............................................................................... - Adjusting sender for accelerator pedal position ....................................................................... - Disassembling and assembling air filter ................................................................................... - Removing and installing injection pump ................................................................................... - Dynamically testing and setting commencement of injection ................................................... - Removing and installing and testing injection nozzles ............................................................. - Wiring and Component Test with Test Box .............................................................................. - Replacing engine control unit ................................................................................................... Inspecting the charge air pressure system .............................................................................. - Inspecting charge air pressure ................................................................................................. - Inspecting charge pressure control solenoid valve (N75) ........................................................ - Inspecting intake manifold temperature sender (G72) ............................................................. - Inspecting intake manifold pressure sender (G71) and altitude sender ................................... - Hose layout plan for charge pressure control ...........................................................................
Testing injection control ............................................................................................................. - Testing injection timing device control range ............................................................................ - Testing the commencement of injection valve (N108) ............................................................. - Inspecting fuel temperature sender ..........................................................................................
23-22 23-22 23-24 23-25 23-26 23-27
23-1 23-1 23-1 23-2 23-2.2 23-3.1 23-4 23-5 23-6 23-7 23-7.2 23-8 23-13 23-16 23-19 23-20
Page
23-28 23-28 23-29 23-30
Edition 01.04 S00.5111.56.20
------------ I ------------
Service
Inspecting control units input quantities .................................................................................. - Testing voltage supply for diesel direct injection system .......................................................... - Testing engine speed sender (G28) ......................................................................................... - Testing needle lift sender (G80) ............................................................................................... - Testing coolant temperature sender (G62) ............................................................................... - Testing brake light switch and brake pedal switch ................................................................... - Testing modulating piston movement sender (G149) and metering adjuster (N146) ............. - Testing accelerator pedal position sender (G79) ...................................................................... Testing auxiliary signals ............................................................................................................. - Testing signals from/to the air conditioning system .................................................................. - Testing clutch pedal switch (F36) ............................................................................................. - Testing speed signal ................................................................................................................. - Testing engine speed signal ..................................................................................................... - Activating or deactivating cruise control system ....................................................................... - Testing cruise control system ................................................................................................... - Testing CAN-Bus databus ........................................................................................................
Inspecting exhaust gas recirculation system ........................................................................... - Inspecting exhaust gas recirculation ........................................................................................ - Inspecting exhaust gas recirculation valve (N18) ..................................................................... - Inspecting air mass meter (G70) .............................................................................................. - Vacuum plan of hose layout plan for the exhaust gas recirculation system .............................
OCTAVIA
23-38 23-38 23-41 23-42 23-43 23-44 23-45 23-47 23-32 23-32 23-34 23-35 23-37
Servicing intake manifold 08.97 ............................................................................................ - Inspecting the change-over of the intake manifold flap ............................................................ - Hose layout plan for intake manifold flap operation .................................................................
23-49 23-49 23-51 23-52 23-53 23-54 23-55 23-55.3 23-56 23-57 23-59
28
Glow plug system
Inspecting glow plug system ..................................................................................................... - Inspecting proper operation ...................................................................................................... - Inspecting glow plugs ............................................................................................................... - Inspecting glow period warning lamp .......................................................................................
28-1 28-1 28-2 28-2
Page
------------ II ------------
Edition 01.04 S00.5111.56.20
OCTAVIA
Self-diagnosis
Self-diagnosis
Features of self-diagnosis
The diesel direct injection system control unit is equipped with a fault memory. The fault memory is designed as a permanent memory and as a volatile memory. If faults occur in the monitored sensors or components, these are stored in the fault memory together with an indication of the fault type. The engine control unit analyses this fault information and distinguishes the fault types page 01-8, Fault Table, and stores these faults until the contents of the fault memory are erased. Faults which occur only temporarily (sporadically), are displayed as sporadic by the addition /SP. The cause of a sporadic fault may be, for example, a loose contact or a temporary open circuit in the wiring. If a sporadic fault no longer occurs within 50 engine starts, it is automatically erased from the fault memory. The stored faults can be read out with the vehicle system tester V.A.G 1552 or V.A.G 1551, or also with VAS 5051 page 01-5. After any faults have been rectified, it is then necessary to erase the fault memory page 01-6. Notes: The description which follows relates only to the vehicle system tester V.A.G 1552 using the programme card version 5.0. If see info in literature appears in the display of the vehicle system tester, look for the appropriate text in the fault table on the basis of the fault code. Use of the fault reader V.A.G 1551 (with programme card version 8.0) with integrated printer, or VAS 5051, is similar. Slight variations are possible in the readouts in the display.
01
Technical data of self-diagnosis

Interrogating control unit version The control unit version is displayed when the vehicle system tester V.A.G 1552 is connected and the engine electronics control unit is selected page 01-2.
Edition 12.00 S00.5111.54.20
------------ 01-5 -----------01-1
01
Self-diagnosis
OCTAVIA
Functions available when using vehicle system tester V.A.G 1552 Please refer to the table below for the requirements necessary to enable you to select the desired functions. Function Condition Engine not running, ignition on 01 Interrogate control unit version yes yes1) yes no Engine idling yes yes
02 Interrogate fault memory 03 Final control diagnosis 04 Basic setting 06 End output 05 Erase fault memory 07 Code control unit
yes yes no
yes
yes yes
08 Read measured value block

1)
yes
yes
yes
yes
Only perform when ignition switched on if engine does not start (operate starter first of all for at least 6 seconds).
Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit
Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Test conditions l Battery voltage at least 11.5 V l Fuse 12 o.k.
------------ 01-2 ------------
l Earth connections at gearbox and on left below battery o.k.
Edition 12.00 S00.5111.54.20
OCTAVIA
Self-diagnosis
K-
Test of vehicle systems Control unit does not answer Test of vehicle systems Error in establishing communication Test of vehicle systems K wire not switching to earth Test of vehicle systems K wire not switching to positive
HELP
HELP
K If one of the following messages appears in the display, perform fault finding according to diagnostic cable fault finding programme: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder, or Operating Instructions of vehicle system tester
HELP
HELP
Test of vehicle systems Enter address word XX
HELP
K Readout in display: -
Edition 12.00 S00.5111.54.20

01
Connect vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C. After the vehicle system tester has been connected: Depending on the desired function, switch the ignition on or start the engine page 01-2, table of Available functions. If the readouts which appear in the display do not correspond to the description in the procedure, refer to the following notes: Notes: If Error in data transmission is displayed because of an input error, disconnect cable at vehicle system tester, plug it in again and repeat the steps. Note: Operate the vehicle system tester on the basis of the readout in the display. Enter address word 01 for Engine electronics and confirm the entry with the key Q.
-----------------------
01
Self-Diagnosis
OCTAVIA
038906018BQ 1.9 l R4 EDC G00SG 2112 Coding 00002 WSC 01234
K The control unit identification appears in the display, e.g.: 1.9 l R4 038906018BQ Part no. of control unit part1) Engine displacement version (4 cyl. in-line engine) Injection system (Electronic Diesel Control) Engine displacement
EDC G or no display 00 MG AG
Vehicle with or without cruise control system Control unit mapping Manual gearbox Automatic gearbox
2112
Coding 00002 Coding variant of control unit WSC 01234
Data status (software version) of control unit
Workshop code from the vehicle system tester V.A.G 1552 with which the last coding was performed
List of all control units Part no. of CU1) 038906018B Software version 1822 2112 1002 Starting date 08.97
038906018GM 038906012H 038906012F
038906018BQ
038906018BC
3313
2162 3315
08.98 04.99 05.99 07.00 08.00 08.03 08.00
08.98
038906012HA
1)
For current control unit version - spare parts catalogue
4922
Notes: If the control unit version displayed does not correspond to the vehicle, replace the control unit page 23-20. Incorrect coding of the engine control unit results in: poor driveability (jerking when changing gears, load alteration shock etc.) Increase in fuel consumption Increase in pollution
------------ 01-4 -------------
Edition 09.03 S00.5111.55.20
OCTAVIA
Self-diagnosis Storage of non-existent faults in fault memory Functions not being performed Reduction in life of automatic gearbox If the code does not match the corresponding version in the vehicle: Check coding of engine control unit page 01-23, Coding engine control unit. Press key.
01
Test of vehicle systems Select function XX
HELP
K Readout in display: For further procedure Repair descriptions.
Interrogating and erasing fault memory

Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Interrogating fault memory Connect vehicle system tester V.A.G 1552 with cable and select engine electronics control unit (address word 01). Engine should be idling for this step. (Connecting vehicle system tester and selecting engine electronics control unit page 01-2).
Only if the engine does not start: Test of vehicle systems Select function XX HELP Switch ignition on.
K Readout in display: Enter 02 for the function Interrogate fault memory and confirm the entry with the key Q.
X faults recognized!
K The number of stored faults or No fault recognized! appears in the display. If no fault is stored: Press key.
HELP
K Readout in display: Enter 06 for the function End output and confirm entry with the key Q.
Edition 12.00 S00.5111.54.20
------------ 01-9 -----------01-5
01
Self-Diagnosis If one or several faults are stored: Press key.
OCTAV1A
Fault number: 00542 Needle lift sender -G80 Short-circuit to earth
K Read-out of fault number on display, e.g.: Press key.
K Fault source and fault type appear in the display, e.g.: Press key.
The stored faults are displayed in sequence. Vehicle system test Select function XX HELP Press key.
K Read-out on display: Enter 06 for the function end output and confim entry with key Q. Rectify fault by referring to the fault table page 01-8.
Note:
When carrying out test and removal and installation operations, faults, such as connectors unplugged, may also be detected by other control units. This is why, when the work is concluded, that it is necessary to interrogate and erase the fault memory on all control units. For this you must proceed as follows: Enter 00 twice for the address word Automatic check sequence and confirm entry with Q key. The -V.A.G 1552- sends all known address words in sequence.
Erasing fault memory Test condition l Rectifying fault Note: After fault elimination the fault memory must again as described be interrogated and subsequently erased. Whenever the fault memory is erased, it is necessary to generate a readiness code page 01-26. Connect vehicle system tester -V.A.G 1552and select the engine electronics control unit (address word 01). The engine must be running in idle. (Connect vehicle system and select engine electronics control unit page 01-2).
Edition 01.04 S00.5111.56.20
For vehicles 08.03
------------ 01-6 -------------
OCTAVIA
Self-Diagnosis
01
HELP
K Readout in display: Press the keys 0 and 2 for the function Interrogate fault memory and confirm the entry with the key Q.
X faults recognized
K The number of stored faults appears in the display. If one or several faults are stored: The stored faults are displayed one after the other.
HELP
K After the stored faults have been displayed, the following readout appears: Press the keys 0 and 5 for the function Erase fault memory and confirm the entry with the key Q.
Test of vehicle systems Fault memory is erased
K Readout in display:
Note: If you have switched off the ignition between Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Press the key. Press the keys 0 and 6 for the function End output and confirm the entry with the key Q. Carry out a road test. During the road test, once again interrogate the fault memory. No further faults should be displayed.
Edition 02.99 S00.5111.53.20
------------ 01-7 ------------
01 Fault table
Notes: For vehicles 08.98 , different fault codes with the same or similar texts are displayed. The required text is to be selected in the fault table according to the fault code. If the display of the vehicle system tester reads Information in the literature the required text is to be found in the fault table according to the fault code. The fault table is ordered according to the fault code on the left.
Self-Diagnosis
Explanations concerning the types of faults (e.g. Interruption or short-circuit to earth):

Readout on V.A.G 1552 old Fault number new Possible cause of fault
00513
Engine speed sender -G28 Implausible signal
16705
No signal
16706
Bent or loose sensor washer Distance to speed sender/ sensor rotor too great Metallic swarf on engine speed sender -G28 Line interruption of screening -G28 defective -G28 defective Line interruption or shortcircuit Line interruption of screening.
Poor starting Irregular engine running, misfiring Increased idling speed Glow period indicator light flashes Reduced performance No display on rev counter Engine does not start
00519
Intake manifold sender -G71 Short-circuit to positive
17563
Line interruption/short-circuit to earth Supply voltage
17564 17565 17566
Short-circuit to positive -G71 defective
Poor performance
Line interruption or shortcircuit to earth -G71 defective Line interruption or shortcircuit
Line interruption or shortcircuit
------------ 01-8 -------------

OCTAVIA
If components are output as faulty: First check all cables and connectors to these components as well as the earth connections according to the Current Flow Diagram. Replace the component only if this test does not reveal any fault. This applies in particular for faults that are output as sporadically occurred (SP) faults. Operating instructions for vehicle system tester
Possible effects Rectifying fault - Remove noise insulation and check sensor washer - Check engine speed sensor page 23-41 - Check intake manifold pressure page 23-26 - Check sender -G71 - Check intake system for leaks page 23-27 Edition 09.03 S00.5111.55.20
OCTAVIA
Self-Diagnosis
01
Readout on V.A.G 1552 Fault number old 00522 Coolant temperature sender -G62 Short circuit to earth -G62 faulty Cable has short circuit to earth Black exhaust when starting Engine preheater does not operate Preglowing always operates for about 20 seconds - Test coolant temperature sender page 23-43 new 17663 Possible cause of fault Possible effects Rectifying fault
Open/short circuit to positive
17664
-G62 faulty Open circuit in wiring or cable has short circuit to positive
00527 Intake manifold temperature sender -G72 Short circuit to earth Open/short circuit to positive 00532 Supply voltage Implausible signal as appropriate Voltage supply tml. 15 Voltage too low
17568
-G72 faulty Cable has short circuit to earth 17569 -G72 faulty Open circuit in wiring or short circuit to positive
Engine preheater does not operate
- Test intake manifold temperature sender page 23-25
18008
Control unit was connected when ignition on Open circuit in wiring or short circuit Voltage not present when ignition on (terminal 15) Engine does not start Engine stops
- Erase fault memory and continue checking vehicle - Test voltage supply of diesel direct injection system control unit page 23-38 - Test voltage supply of terminal 15 Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder - Replace control unit page 23-20 - Test voltage supply of diesel direct injection system control unit page 23-38
Edition 02.99 S00.5111.53.20
------------

------------
Diesel direct injection system control unit -J248 faulty Voltage supply relay terminal 30 (J322) faulty
01
Self-Diagnosis
OCTAVIA
Readout on V.A.G 1552 Fault number old 00539 Fuel temperature sender -G81 Short circuit to earth Open/short circuit to positive 17571 -G81 faulty Cable has short circuit to earth -G81 faulty Open circuit in wiring or short circuit to positive Connector for injection pump separated 00542 Needle lift sender -G80 Short circuit to earth -G80 faulty Open circuit in wiring or short circuit 17654 Fuel supply (was) interrupted: tank has run empty, feed line or filter blocked, system drawing in air (Sporadic) open circuit in wiring to fuel cut-off valve Glow indicator lamp flashes Rough engine running Reduced output Fault 00550 Commencement of injection control possible Misfiring, jerking - Test needle lift sender page 23-42 17653 Several faults stored Engine stops - Check plug connection for injection pump Reduced output - Test fuel temperature sender page 23-30 new 17570 Possible cause of fault Possible effects Rectifying fault
Implausible signal
- Check fuel system
Engine stops Misfiring
- Check cable connection and plug connection at injection pump - Take off oil pan and inspect sender plate
Sender plate of engine speed sender bent or loose -G80 faulty
Misfiring at exactly 3000 rpm
Misfiring, jerking (particularly at high revs) Fault 01268 quantity adjuster control difference stored Irregular engine running, misfiring No throttle response after overrun Glow indicator lamp flashes Misfiring, jerking Reduced output
- Replace needle lift sender
Injection pump faulty
- Replace injection pump
Open/short circuit to positive
17655
-G80 faulty Sporadic open circuit in wiring (cable break)
- Test needle lift sender page 23-42
------------ 01-10 ------------
Edition 02.99 S00.5111.53.20
OCTAVIA
Self-Diagnosis
01
Readout on V.A.G 1552 Fault number old 00545 Engine/gearbox electrical connection 1) Open circuit in wiring or short circuit 00550 Commencement of injection control Control difference Commencement of delivery not o.k. Adjustment travel of injection pump blocked (dirt, swarf) Engine was stalled (within the last 50 starts) Fuel feed (was) interrupted: tank has run empty, feed line or filter blocked, system drawing in air Open circuit in wiring to commencement of injection valve -N108 Fault 00542 Needle lift sender implausible signal may be stored Poor performance at higher revs Engine difficult to start Poor performance at higher revs - Test and set commencement of injection page 23-13 - Test injection timing control range page 23-28 - Erase fault memory, continue checking vehicle - Check fuel system 17656 Hard gearshifts - Test signals from/to automatic gearbox A - Signal for gearshift new Possible cause of fault Possible effects Rectifying fault
Engine clatters when idling as commencement of injection constantly advanced Several faults may be stored
- Test commencement of injection valve page 23-29 - Test fuse - Replace commencement of injection valve
Commencement of injection valve -N108 worn
No constant commencement of injection possible at Basic setting (display block 2 varies over more than 10 readouts) Irregular engine running, poor performance
1)
Not available at present.
Edition 02.99 S00.5111.53.20
------------ 01-11 ------------
01
Self-Diagnosis
OCTAVIA
Readout on V.A.G 1552 Fault number old 00553 Air mass meter -G70 Implausible signal Engine was stalled (within the last 50 starts) Battery weak Poor performance Air mass constantly indicated in measured value block Misfiring, jerking Fault 00542 Needle lift sender implausible signal possible or open/short circuit to positive Irregular idling, poor performance - Erase fault memory, continue checking vehicle - Test battery new 16485 Possible cause of fault Possible effects Rectifying fault
Sporadic open circuit in wiring (cable break) to needle lift sender -G80
- Test needle lift sender page 23-42
Air filter blocked Vacuum hoses of exhaust gas recirculation incorrectly connected or mechanical EGR valve constantly open Air mass meter faulty Open/short circuit to earth 17552 -G70 faulty Open circuit in wiring or short circuit to earth -G70 faulty Open circuit in wiring or short circuit to positive Open circuit in wiring or short circuit
- Inspect intake system - Inspect vacuum hoses page 23-37
Poor performance, jerking Reduced output Black exhaust possible when accelerating from low revs
- Test air mass meter page 23-35
Short circuit to positive Supply voltage 00575 Intake manifold pressure Control difference if appropriate Charge pressure Control difference
17553
17554 17958
------------

------------
Hoses wrongly connected, not fitted on, blocked, leaking Turbocharger vacuum unit faulty Charge pressure control solenoid valve -N75 faulty
Sudden drop in power Reduced output
- Test charge pressure page 23-22 - Inspect charge pressure hoses page 23-27
Edition 02.99 S00.5111.53.20
OCTAVIA
Self-Diagnosis
Readout on V.A.G 1552 old Fault number new
Possible cause of fault
Possible effects
00625
Speed signal Implausible signal If necessary Vehicle speed signal Implausible signal Vehicle speed signal Signal too great
16885
Line interruption between speedometer sender -G22 and dash panel insert -G22 defective Speedometer -G21 defective Line interruption between dash panel insert and engine control unit CCS not operational Air conditioning not operational Possible load alteration shock
- Check speed signal page 23-52 - Check speedometer sender Electrical System; Repair Group 90
17948 18024
00626
Glow period warning lamp -K29 Short-circuit to positive Short-circuit to positive Glow period warning lamp not operational Glow period warning lamp not operational Glow period warning lamp lights up constantly
Line interruption/short-circuit to earth
18025
Line interruption Bulb defective Short-circuit to earth
- Check glow period warning lamp page 28-2
00668
Onboard voltage, terminal 30 Implausible signal
18009
Diesel direct injection system relay -J322 jams
Engine does not start (safety deactivation)
00671
Cruise control system switch -E45 Undefined switch status
- Test voltage supply for diesel direct injection system page 23-38
E45 defective Line interruption or shortcircuit
Cruise control system not operational
- Check cruise control system page 23-55 - Reading measured value block 6 page 01-35
Edition 09.03 S00.5111.55.20

01
Rectifying fault ------------ 01-13 -------------
01
Self-Diagnosis
OCTAVIA
Readout on V.A.G 1552 Fault number old 00741 Brake pedal monitoring Implausible signal Switch incorrectly set Open circuit in wiring -F or -F47 faulty Fuse faulty Both brake lights faulty 17762 Preglow indicator lamp flashes Fuse or brake light faulty - Test -F and -F47 and set page 23-44 - Test fuse and brake light new Possible cause of fault Possible effects Rectifying fault
00765 Modulating piston movement sender -G149
10-pin connector for injection pump separated Injection pump faulty Open circuit in wiring or short circuit 00777 Accelerator pedal position sender -G79 Signal too large Open circuit in wiring -G79 faulty (idling switch) 18040 18047 Open circuit in wiring or short circuit Open circuit in wiring -G79 faulty (idling switch) 18039
Several faults stored Engine stops Drivability problems Engine stops
- Inspect plug connection of injection pump - Test modulating piston movement sender page 23-45
Voltage supply Implausible signal as appropriate Accelerator pedal position sender 1/2 -G79+-G185 1) Implausible signal Short circuit to positive 01044 Engine control unit incorrectly coded
Speed governed to approx. 1100 rpm as safety measure No throttle response Preglow indicator light flashes Fast idling speed
- Test accelerator pedal position sender page 23-47
18020
Short circuit to positive -G79 faulty
Invalid control unit coding
Preglow indicator light flashes
- Code control unit page 01-23
1)
Incorrect fault text readout. The correct readout is: Accelerator pedal position sender -G79
------------ 01-14 ------------
Edition 02.99 S00.5111.53.20
OCTAVIA
Self-Diagnosis
Readout on V.A.G 1552 old Fault number new
Possible effects
01117
Load signal for generator tml. DF Implausible signal
17911
Line interruption between AC generator and diesel direct injection system control unit -J248 AC generator defective Voltage regulator on AC generator defective
Auxiliary heater not operational
01180
Engine/air conditioning compressor electrical connection Short-circuit to positive
- Check wiring Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting locations - Check AC generator Repair Group 27; AC generator - Reading measured value block, display group 016 page 01-37
Short-circuit in the wiring
01193
Low heat output relay -J359 Line interruption or short-circuit to earth
19460
Reduced vehicle acceleration, when the air conditioning system is switched on
- Testing signals from/to the air conditioning system page 23-49.
Line interruption
Engine preheating not operational
Low heat output relay -J359 defective Short-circuit to earth
Engine preheating is on
- Check wiring Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting locations - Check low heat output repage 01-18, Actualay tor diagnosis
Short-circuit to positive
19459
Edition 09.03 S00.5111.55.20

01
Rectifying fault ------------ 01-15 -------------
01
Readout on V.A.G 1552 old Fault number
Self-Diagnosis
OCTAV1A
01194
High heat output relay -J360 Line interruption or short-circuit to earth
new
Possible effects
Rectifying fault
19462
Line interruption
High heat output relay -J360 defective Short-circuit to earth Short-circuit to positive
Engine preheating is on
- Check wiring Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations - Check high heat output relay page 01-18, Actuator diagnosis
19461 17945
01237
Fuel shut-off valve -N109 Mechanical fault or Malfunction -N109 defective, leaking or jammed Reduced performance Engine stoppage Engine stoppage - Check -N109 page 01-18, Actuator diagnosis - Check wiring Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
01262
17946 17954
-N109 defective Line interruption or shortcircuit to earth
Charge pressure solenoid valve -N75 Short-circuit to positive Short-circuit to earth Short-circuit to positive Reduced performance Charge pressure too low Reduced performance Charge pressure too high Reduced performance Charge pressure too low - Check charge pressure solenoid valve page 23-24
17955 17957
Short-circuit to earth Line interruption Solenoid valve defective
------------ 01-16 -------------
Edition 01.04 S00.5111.56.20
OCTAV1A
Self-Diagnosis
01
01265
Exhaust gas recirculation valve -N18 Short-circuit to positive
new
Possible effects
Rectifying fault
17810
17849
Line interruption Solenoid valve defective Short-circuit to earth
No exhaust gas recirculation No exhaust gas recirculation
01266
Glow plug relay -J52 Short-circuit to positive
18026
Too much exhaust gas recirculation Reduced performance, black smoke
- Check exhaust gas recirculation valve -N18 page 23-24
18027
Line interruption Relay defective Short-circuit to earth
Glow plug system not operational Glow plug system not operational Glow plug system not operational
- Check glow plug relay -J52
Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
01268
Metering adjuster -N146 Control difference (deviation) upper limit value lower limit value
17969
17970 17971
Metering mechanism adjusted Metering mechanism adjusted
Injection pump defective, leaking Line interruption or shortcircuit
Incorrect driving behaviour Engine stoppage Jerking, poor performance Black smoke Irregular engine running
- Check metering adjuster -N146 page 23-45 - Replace injection pump page 23-8
Edition 01.04 S00.5111.56.20
------------ 01-17 -------------
01
Self-Diagnosis
OCTAV1A
01269
Commencement of injection valve -N108 Short-circuit to positive Line interruption/short-circuit to earth
new
Possible effects
Rectifying fault
17659
17660
Valve defective
Engine jerks when idling because commencement of injection is constantly adjusted to advance.
Line interruption (fuse) Short-circuit to earth
Engine jerks when idling because commencement of injection is constantly adjusted to advance. Poor performance because commencement of injection is constantly adjusted to late
- Check commencement of injection valve page 23-29 - Check fuse - Check commencement of injection valve page 23-29
Possible that several faults are stored
For vehicles 08.97 01282

Variable intake manifold flap change-over valve -N239 Line interruption/short-circuit to earth Short-circuit to positive
19561
19560
Line interruption Variable intake manifold flap change-over valve defective Short-circuit to positive
Hard engine knock
- Check Variable intake manifold flap change-over valve -N239 page 23-57
------------ 01-17.1 -------------
Edition 01.04 S00.5111.56.20
OCTAV1A
Self-Diagnosis
01
16500
Coolant temperature sender -G62 Implausible signal
new
Possible effects
Rectifying fault
Sender for coolant temperature -G62 supplies implausible signal caused by loose contact or corrosion due to humidity in the connector Signal input in engine control unit defective (control unit defective Coolant regulator defective (thermostat)
Cold-start difficulties at very low temperatures Poor driveability during warm-up Increase in fuel consumption Increased emission levels
- Reading measured value block, display group 007 page 01-51 - Check -G62 page 23-43
- Replacing engine control unit page 23-20 - Check coolant regulator 1.9 l/66 kW (TDI) Engine, Mechanical Components; Repair Group 19
16955
Brake light switch -F Implausible signal
17811
Exhaust gas recirculation system Control deviation
Brake light defective Brake light does not light Line interruption or shortup circuit to positive or earth Engine speed fluctuations between brake light switch during braking and engine control unit Exhaust gas recirculation valve -N18- defective Exhaust gas recirculation system not operational
- Check brake light switch and brake pedal switch page 23-44
- Check exhaust gas recirculation solenoid valve page 01-18, Actuator diagnosis - Check exhaust gas recirculation valve 1.9 l/66 kW (TDI) Engine, Mechanical Components; Repair Group 26
Exhaust gas recirculation potentiometer -G212- defective
Mixture adaptation not operational
Edition 01.04 S00.5111.56.20
------------ 01-17.2 -------------
01
Self-Diagnosis
OCTAV1A
17931
Crash signal of airbag CU Implausible signal
new
Possible effects
Rectifying fault
Fault in airbag system
17964
Charge pressure control Regulating limit not reached
Airbag warning light comes - Check airbag on Body Work; Repair Group 01
Fault in charge pressure control -N75 defective
Incorrect driving behaviour Reduced performance
17965
Charge pressure control Regulating limit exceeded
- Check charge pressure control solenoid valve -N75 page 01-18, Actuator diagnosis - Check charge pressure control 1.9 l/66 kW (TDI) Engine, Mechanical Components; Repair Group 21
Fault in charge pressure control -N75 defective
Incorrect driving behaviour Reduced performance
17977
Cruise control system switch (CCS) -E45 Implausible signal
- Check charge pressure control solenoid valve -N75 page 01-18, Actuator diagnosis - Check charge pressure control 1.9 l/66 kW (TDI) Engine, Mechanical Components; Repair Group 21
Cruise control system switch defective Line interruption
Cruise control system not operational
- Check cruise control system page 23-54 - Reading measured value block 6 page 01-35
------------ 01-17.3 -------------
Edition 01.04 S00.5111.56.20
OCTAV1A
Self-Diagnosis
01
17978
Engine control unit blocked
new
Possible effects
Rectifying fault
Manipulation attempt Start attempt with an adapted ignition key Engine control unit not adapted to immobiliser control unit Short-circuit in communication cable Fault in the immobiliser system Immobiliser control unit defective/missing Engine control unit wrongly coded
Engine starts and stops immediately
- Adapt engine control unit to immobiliser Binder: Electrical system; Repair Group 90
- Check immobiliser Binder: Electrical system; Repair Group 90

Data bus drive Missing message from transmission CU
- Code engine control unit page 01-23
Databus lines to automatic transmission control unit interrupted Fault in the system of the automatic transmission
Poor driveability (jerking - Check data bus page when changing gears, load 23-55.3 alteration shock etc.)
18044
Data bus drive Missing message from Airbag CU
Databus lines defective Fault in ABS system Incorrect driving behaviour
- Check automatic transmission control unit Binder: Automatic transmission
- Check data bus page 23-55.3
18050
Fault in airbag system Warning light for airbag comes on Check airbag Body Work; Repair Group 01
Read out fault memory of airbag control unit
Edition 01.04 S00.5111.56.20
------------ 01-17.4 -------------
01
Self-Diagnosis
OCTAV1A
18058
Data bus drive Missing message from instrument cluster
new
Possible effects
Rectifying fault
Databus lines defective Incorrect or defective dash panel insert Incorrect or defective engine control unit Fault in ABS control unit Poor driveability - Check data bus page 23-55.3
18061
Read out fault memory of ABS control unit
18062
Oil level/oil temperature sender -G266 defective
No vehicle dynamics control - Check ABS control unit TCS not operational Binder: Chassis; Antilock MSR not operational Brake System Warning light for oil level comes on - Check oil level/oil temperature sender -G266 Binder: Electrical System; Repair Group 90
Read out fault memory of instrument cluster
18065
Air conditioning input/output Short-circuit to positive
Short circuit in wiring
Reduced performance
18090
Data bus drive Implausible signal from ABS control unit
Databus lines to ABS con- No vehicle dynamics control unit interrupted trol TCS not operational MSR not operational Fault in ABS system
- Check air conditioning compressor engagement page 01-18, Actuator diagnosis
- Check data bus page 23-55.3 - Check ABS control unit Binder: Chassis; Antilock Brake System
------------ 01-17.5 -------------
Edition 01.04 S00.5111.56.20
OCTAV1A
Self-Diagnosis
01

Data bus drive Missing message from ABS CU
new
Possible effects
Rectifying fault
18057
Databus lines to ABS control unit interrupted No vehicle dynamics control - Check data bus page 23-55.3 - Check ABS control unit Binder: Chassis; Antilock Brake System
Fault in ABS system

Data bus drive
18056
Databus lines to auto Poor driveability matic transmission or ABS (jerking when changing control unit interrupted gears, load alteration shock etc.) Fault in automatic transmission or ABS system Mixture adaptation not operational - Check data bus page 23-55.3
Hardware defective or defective
19458
Kick-down switch F8 Implausible signal
- Check ABS control unit Binder: Chassis; Antilock Brake System - Check automatic transmission control unit Binder: Automatic transmission
Accelerator pedal position sender -G79 defective
Shifting points for automatic gearbox N.O.K.
65535
Control unit defective
16989 17795 18048

Engine control unit internally defective Poor driveability Engine stoppage Glow period indicator light flashes
- Check accelerator pedal position sender -G79 page 23-47
- Replace engine control unit page 23-20
Edition 01.04 S00.5111.56.20
------------ 01-17.6 -------------
01
Self-Diagnosis
OCTAVIA
Actuator diagnosis
Performing actuator diagnosis
With the actuator diagnosis the following parts are activated in the sequence indicated: 1. Commencement of injection valve (N108) 2. Exhaust gas recirculation valve (N18) 3. AC compressor engagement 4. Fuel shut-off valve (N109) 5. Charge pressure control solenoid valve (N75) 6. Glow plug relay (J52) 7. Glow period warning lamp (K29) 8. Low heat output relay (J359) 1) 9. High heat output relay (J360) 1) 10. Fault lamp 2)
1) 2)
Only for vehicles with special equipment For vehicles as of 08.03.
Test preconditions for vehicles with air conditioning l Vehicle at room temperature (at least + 15C)
l Lowest temperature and highest blower speed preselected Special tools, aids and testers required
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Procedure -
Connect vehicle system tester V.A.G 1552 and select engine electronics control unit (address word 01). The engine must be running in idle page 01-2).
Vehicle system test Select function XX
HELP
K Read-out on display:
------------ 01-18 -------------
Edition 09.03 S00.5111.55.20
l Air conditioning switched on
OCTAVIA
Self-Diagnosis
01
Press keys 0 and 3 for the function Final control diagnosis.
Test of vehicle systems 03 - Final control diagnosis Final control diagnosis Start of injection valve -N108
If no change in the combustion noise can be heard: Final control diagnosis EGR valve -N18 Test injection timing device control range page 23-28.
Note:
The clicking of the valve cannot be heard because of the engine noise and should therefore be felt by touching.
If the valve does not click: Final control diagnosis AC compressor cut-off Test EGR valve
If the AC compressor is not switched off: Test AC compressor cut-off
Edition 05.97 S00.5111.51.20

Confirm the entry with the key Q. When the valve is actuated, this results in a clearly audible change in the combustion noise (diesel noise). Press the key. The valve should click. page 23-34. Press the key. What is tested is the AC compressor cutoff. The test step is also displayed in the case of vehicles without air conditioning. The AC compressor should stop within 5 seconds (visual inspection with electric torch), and then start and stop again approximately every 5 seconds. page 23-49.
------------ 01-19 ------------
01
Self-Diagnosis
OCTAVIA
Final control diagnosis Fuel cut-off valve -N109
Press the key.
K Readout in display: The engine should stop. If the engine does not stop: Switch off the ignition. Unscrew fuel cut-off valve and clean any metal swarf and dirt. Repeat final control diagnosis; if the engine again does not stop, replace fuel cut-off valve. Press the key.
Final control diagnosis Charge pressure control solenoid valve -N75
Final control diagnosis Glow plugs relay -J52
Final control diagnosis Glow period warning light -K29
------------

K Readout in display: The solenoid valve should click.
Note:
It is very difficult to hear the clicking of the valve and it should therefore be checked by touching.
If the solenoid valve does not click: -
Test charge pressure control solenoid valve page 23-24.
Press the key.
The relay should click.
Because of the high power consumption of the glow plugs, it is also possible to check that the relay switches on and off by observing how the interior light becomes dimmer and then brighter.
If the relay does not click: -
Test glow plugs relay Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
Press the key.
The warning light should flash.
------------
Edition 05.97 S00.5111.51.20
OCTAVIA
Self-Diagnosis If the warning lamp does not flash: Check glow period warning lamp page 28-2. Press key.
01
Actuator diagnosis Low heat output relay -J359
K Read-out on display: The relay valve must click. If the relay does not click: - Check low heat output relay: Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting locations. Press key.
Actuator diagnosis High heat output relay -J360
K Read-out on display: The relay valve must click. If the relay does not click: - Check low high heat output relay: Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting locations. Press key.
Actuator diagnosis Fault lamp
K Read-out on display: The fault lamp must flash. If the fault lamp does not flash: - Check fault lamp Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting locations Press key.
HELP
K Read-out on display: Enter 06 for the function end output and confim entry with key Q.
Basic setting
Test conditions l Coolant temperature at least 80 C l Electrical consumers must be disconnected (the radiator cooling fan must be off during this test) l Air conditioning switched off
Edition 09.03 S00.5111.55.20
------------ 01-21 -------------
01
Self-Diagnosis Special tools, aids and testers required
OCTAVIA
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A, 3B or 3C. Procedure -
Connect vehicle system tester V.A.G 1552 and select engine electronics control unit (address word 01). The engine must be running in idle. (Connect vehicle system tester and select engine electronics control unit page 01-2).
HELP
K Read-out on display: -
Enter 04 for the function Basic setting and confirm entry with the key Q.
Basic setting Enter display group number XXX System in Basic setting 1 2 3 4 5 0
HELP
K Read-out on display: -
Enter 000 and confirm entry with the key Q.
10
K Read-out on display: (1... 10 = Display fields)
Display group 000 in idle (warm engine, coolant temperature not below +85 C)
This display group serves as a dynamic test of the commencement of injection. The commencement of injection valve (N108) is constantly actuated, so that the injection timing device is retarded.
System in Basic setting 42 46 0 20 90 201 64 0 153 127 83 Ignore K Read-out on display:
Fuel temperature: at approx. 40 C (if the temperature is not reached at a low outside temperature, ignore specified value)
Ignore
Coolant temperature: approx. 90 C
Ignore
Ignore
Ignore
Accelerator pedal position: 0
The commencement of injection is dependent on the fuel temperature, specified values page 23-13, Dynamically test and set commencement of injection Idling speed: 41...441)
1)
For vehicles 07.97 = 41...44 For vehicles 08.97 = 42...45 For vehicles 05.99 = 43...46
------------ 01-22 -------------
Edition 09.03 S00.5111.55.20
OCTAVIA
Self-diagnosis
01
Coding control unit

If the code which is displayed does not match the vehicle, or if the control unit has been replaced, it is then necessary to code the control unit as follows. Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Test procedure Connect vehicle system tester V.A.G 1552 and select engine electronics control unit (address word 01). The ignition must be switched on for this step page 01-2.
HELP
K Readout in display: Enter 07 for the function Code control unit and confirm the entry with the key Q.
Code control unit Enter code number XXXXX
Q (0-32000)
K Readout in display: Enter the relevant code number for this vehicle and confirm the entry with the key Q.
Coding control units Models 07.97 Models 08.97
Code number 00001 00002
Models fitted with Automatic gearbox Manual gearbox
Code number 00001 00002 00003
Models fitted with Automatic gearbox
Manual gearbox with activated CAN databus (models with ABS) Manual gearbox without CAN databus (models without ABS) Manual gearbox for 4x4 models
00005
038906018.. 1.9l R4 EDC G00SG 1822 Coding 00002 WSC 01234
K The control unit identification is shown in the display (example): Switch ignition off and on again.
Notes: The code entered is activated when the ignition is switched on again
If the ignition is not switched off and on again after entering the valid code, it is then not possible to erase the fault 01044 Control unit incorrectly coded. Press key.
Edition 12.00 S00.5111.54.20
------------ 01-23 ------------
01
Self-Diagnosis
OCTAV1A
HELP
K Read-out on display Enter 06 for the function end output and confirm entry with the key Q.
Readiness code
Valid for vehicles 08.03
Reading readiness code

Function
The readiness codes are two 8-digit numerical codes which indicate the status of the emission-relevant diagnoses. If the diagnosis for a system was successfully performed (e.g. exhaust gas recirculation system), the relevant position of the numerical code is set from 1 to 0. This diagnosis is performed at regular intervals during normal driving. After repairs have been carried out to an emission-relevant system, it is recommended to generate the readiness code in order to thus ensure that the systems operate properly. If a fault is detected during diagnosis, it is then stored in the fault memory. The readiness code is erased through deletion of the fault memory, that is all relevant points will be set to 1. Generation of the readiness code means to activate the diagnostic functions such as diagnosis of fuel supply, diagnosis of other systems etc. Procedure Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3CConnect vehicle system tester -V.A.G 1552and enter address word 01 Engine electronics, ignition switched on page 01-24.
------------ 01-24 -------------
Edition 01.04 S00.5111.56.20
OCTAV1A
Self-Diagnosis Read function 08 Reading measured value block and select display group 017.
01
Reading measured value block 00000000 00000110 10000000
17
00000000
K Read-out on display
Meaning of 8-digit numerical block for readiness code in display field 2 1 2 3 4 5 6 7 1 8 0 Ignore Ignore Ignore Ignore Meaning
Ignore
Diagnosis of fuel supply Ignore
Diagnosis of other systems
Meaning of 8-digit numerical block for readiness code in display field 4 1 2 3 4 5 6 7 0 8 0 Ignore Ignore Ignore Ignore Ignore Diagnosis of exhaust gas recirculation system Ignore Meaning
Ignore
Edition 01.04 S00.5111.56.20
------------ 01-25 -------------
01
Self-Diagnosis -
OCTAV1A
If the specified values are not reached, generate readiness code page 01-26. Press key. Enter function 06 End output and switch off ignition.
Generating readiness code

Special tools, aids and testers required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3CTest conditions l All electrical consumers such as e.g. light and rear window heater must be switched off. l Intake air temperature below 60 C display group 007, display field 3 l Coolant temperature at least 83 C display group 007, display field 4 Procedure Connect vehicle system tester -V.A.G 1552and enter address word 01 Engine electronics, ignition switched on page 01-2.
Note:
Certain steps must be carried out twice, in order to achieve the readiness code. Work step 1: X fault detected Interrogating fault memory
Enter function 02 Interrogating fault memory and confirm entry with key Q.
K The number of stored faults or No fault detected appears in the display. If a fault is stored: Rectify fault by referring to the fault table page 01-8.
If no fault is stored: Press.
------------ 01-26 -------------
Edition 01.04 S00.5111.56.20
OCTAV1A
Self-Diagnosis Work step 2: Erasing fault memory
01
Vehicle system test Fault memory is erased
K-
Enter function 05 Erasing fault memory and confirm entry with key Q.
Note:
Readiness code is erased each time the fault memory is erased. If the ignition is switched off during Interrogating fault memory and Erasing Fault memory, the fault memory is not erased. Press. Switching off ignition Work step 3: -
Wait at least 5 seconds with ignition OFF.
Note:
This point is important, because with certain diagnoses the slowing down of the control unit must be ended. Otherwise readiness code cannot be generated. Work step 4: Switching on ignition
Charge pressure sender is adapted with atmospheric charge pressure sender. Work step 5: 1st test of fuel supply and other systems Reading measured value block 1 2500/rpm 4.6 mg/h 2.0 CA KStart engine. Select function Reading measured value block and display group 001. For 5 seconds increase the engine speed to 2500 rpm and then run engine at idling speed. 1st test of exhaust gas recir-
94.2 C
Work step 6: culation Reading measured value block 1 1650/rpm 4.1 mg/h 4.0 CA 93.2 C K-
Increase engine speed to 1600 rpm up to 1700 rpm and maintain it for at least 10 seconds in this range.
In this speed range, the exhaust gas recirculation is active and the control difference is checked. (Condition for readiness code to generate exhaust gas recirculation).
Edition 01.04 S00.5111.56.20
------------ 01-27 -------------
01
Self-Diagnosis Work step 7: Work step 8: Switching off ignition Switching on ignition
OCTAV1A
Wait at least 10 seconds with ignition ON.
Work step 9: 2nd test of fuel supply and other systems Reading measured value block 1 2500/rpm 4.6 mg/h 2.0 CA KStart engine. Select function Reading measured value block and display group 001. For 5 seconds increase the engine speed to 2500 rpm and then run engine at idling speed.
94.2 C
Work step 10: 2nd test of exhaust gas recirculation Reading measured value block 1 1650/rpm 4.1 mg/h 2.0 CA 93.2 C KIncrease engine speed to 1600 rpm up to 1700 rpm and maintain it for at least 10 seconds in this range. Press C. Enter 017 for display group 017 and read readiness code.
Reading measured value block 17 00000000 00000110 10000000 00000000
K Specified value in display field 2: 00000110 Specified value in display field 4: 000000000 Press. If the specified values are not reached, repeat procedure for generating readiness code page 01-26.
------------ 01-28 -------------
Edition 01.04 S00.5111.56.20
OCTAV1A
Self-Diagnosis
01
Work step 11: Interrogating fault memory X fault detected! Enter function 02 Interrogating fault memory and confirm entry with key Q.
K The number of stored faults or No fault detected appears in the display. If a fault is stored: Rectify fault by referring to the fault table page 01-8 and re-generate the readiness code page 01-26.
If no fault is stored: Reading measured value block 17 00000000 00000110 10000000 00000000 Press.
K Readiness code was successfully generated, if no fault is stored after two work sequences of the test procedure in the fault memory for the engine control unit and if the following display appears in the channel 017.
Edition 01.04 S00.5111.56.20
------------ 01-28.1 -------------
01
Self-Diagnosis
OCTAVIA
Measured value blocks

Reading measured value block
Test conditions l Coolant temperature at least 80 C l Electrical consumers must be disconnected (the radiator cooling fan must be off during this test) l Air conditioning switched off l No fault in fault memory Special tools, aids and testers required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3C-. Procedure Connect vehicle system tester V.A.G 1552 and select engine electronics (address word 01). The engine must be running in idle.
HELP
K Read-out on display: Enter 08 for the function Read measured value block and confirm entry with the key Q.
Reading measured value block Enter display group number XXX
HELP
K Read-out on display: Enter the desired display group number and confirm entry with the key Q.
Note: Display group number 000 is an example to represent the sequence. Reading measured value block 1 2 3 4 5 6 Vehicle system test Select function XX 7 0 8 9 10 HELP K Read-out on display, e.g.: Press key.
K Read-out on display: Enter 06 for the function End output and confirm entry with the key Q.
------------ 01-28.2 -------------
Edition 09.03 S00.5111.55.20
Specified readouts for general vehicle check
Display group 000, engine idling (engine warm, coolant temperature not less than +85 C) for models 07.97
Read measured value block 42 50 0 20 0 K Readout in display
90
201
Idling speed: 41...44 o.k. if not within tolerance
Commencement of injection: 20...60 o.k. if not within tolerance page 01-42, display group 004 page 01-46, display group 002
Injected quantity: 10...30 o.k. if not within tolerance page 01-38, display group 001
Edition 12.00 S00.5111.54.20

64 153 127 83 Charge pressure: ignore Ambient air pressure: no specification Coolant temperature: 80...51 o.k. > 80: warm up engine Intake manifold temperature: no specification Fuel temperature: no specification Inducted air mass 70...110 o.k. if not within tolerance page 01-49, display group 003 ------------ 01-29 ------------
OCTAVIA
Self-diagnosis
01
01
Display group 000, engine idling (engine warm, coolant temperature not less than +80 C) for models 08.97 04.99
------------
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Self-diagnosis
OCTAVIA
90
201
64
153
127
83
Inducted air mass not tolerance
display
003
Intake
air
up
not
pedal
1 tolerance 0
display
001
not
tolerance
display
004
not
tolerance
display
002
is
measured values apply in speed
recirculation system is about 2 minutes; necessary
blip
or
recirculation
------------
Edition 12.00 S00.5111.54.20
OCTAVIA
90
201
Idling speed: 43...46 o.k. if not within tolerance

1)
Commencement of injection: 12...75 o.k. if not within tolerance page 01-45, display group 004 page 01-46, display group 002
Injected quantity: 15...45 o.k. if not within tolerance page 01-39, display group 001
The measured values apply when the exhaust gas recirculation system is switched on. The exhaust gas recirculation is switched off in the idling speed range after about 2 minutes; if necessary briefly blip throttle or re-start engine.
Edition 12.00 S00.5111.54.20

Self-diagnosis
01
64
153
127
83
Charge pressure: ignore
Ambient air pressure: ignore
Coolant temperature: 80...35 o.k. > 80: warm up engine
Intake manifold temperature: 190...80
Fuel temperature: 91...201
Inducted air mass 1) 69...110 o.k. if not within tolerance page 01-50, display group 003
------------ 01-31 ------------
Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +85 C) for models 07.97 Notes: Accelerate the vehicle at full throttle for the test.
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
Read measured value block 0 186 225 255 186 186 K Readout in display
201
Engine speed: 160...190 (do not exceed 4000 rpm, engine speed is governed)
Commencement of injection: 180...245 (dependent on engine speed) if not within tolerance page 01-42, Display group 004
Accelerator pedal: 255 (depressed fully)
Injected quantity: 170...195 (full load injected quantity) o.k. 125: emergency injected quantity, system fault detected
Charge pressure: 171...191 o.k. if not within tolerance page 01-58, display group 011
------------ 01-32 ------------

64 138 175 233 Ambient air pressure: ignore Coolant temperature: 80...51 o.k. > 80: warm up engine Intake manifold temperature: no specification Fuel temperature: no specification Inducted air mass: > 210 o.k. < 210 page 01-55, display group 010 page 01-5, Interrogating fault memory Edition 12.00 S00.5111.54.20
01
Self-diagnosis
OCTAVIA
Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80 C, engine speed 2900...3100 rpm) for models 08.97 04.99 Notes: Accelerate the vehicle at full throttle for the test.
Read measured value block 0 205 255 K Readout in display
Edition 12.00 S00.5111.54.20
) ) 9$ ) )$ ( 3 3 0 6 # ' $ $ 4 ( ) $ $ % ' ( ) )@ )) 3 7 $ 8 #& ) 5 $ ) 00 ! ) "7 3 0 1 1 0 0 23 " ' 5 5 030 70
201 175 255 Coolant temperature: up air pressure: Intake manifold temperature: temperature: Inducted air mass: 255 255 display 010 Injected quantity: 125: pressure: if not tolerance Commencement of injection: if not tolerance speed: pedal: 255 (depressed fully) (full load injected quantity) injected quantity system fault detected (dependent on Display speed) display 011 fault memory ------------ 01-33 ------------
OCTAVIA
Self-diagnosis
01
01
Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80 Notes: Accelerate the vehicle at full throttle for the test.
Read measured value block 205 255 0 K Readout in display
------------
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Self-diagnosis
OCTAVIA
engine
201
175
255
Coolant temperature: up air pressure:
Intake manifold temperature:
temperature:
Inducted air mass: 255 255
display
010
Injected quantity: 125:
pressure: if not tolerance
Commencement of injection: if not tolerance speed:
pedal: 255 (depressed fully)
(full load injected quantity) injected quantity system fault detected (dependent on Display speed)
display
011
fault memory
------------
Edition 12.00 S00.5111.54.20
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Edition 12.00 S00.5111.54.20 Display 2 Read measured value block
Display group
OCTAVIA
operating state of
ignition
pedal depressed
pedal and brake pedal not depressed
pedal depressed
pedal and brake pedal depressed
pedal
state of pedal and pedal
pedal monitor
pedal depressed
on
pedal
state
able
Self-diagnosis
K Readout in display
Cruise
(CCS)
able
state
pedal depressed
pedal depressed
pedal
pedal
able
operated
to
state of pedal positions = 1
point
closed
opened
opened
Display
------------
display
------------
01
01
------------
$ ! " # $ ! " #

Self-diagnosis state 0 1 Model fitted with CCS - CCS switched off Model fitted with CCS - CCS switched on state 2 5 5 Model without CCS, CCS function is not activated in engine control unit
------------
OCTAVIA
Edition 12.00 S00.5111.54.20
OCTAVIA
Display group 016, engine idling
Read measured value block 70.0 % 10000001 16
Self-diagnosis
00
13.8 V
Generator load: ignore
Operating state of auxiliary heater
Actuation of heating elements
Supply voltage of control unit: ignore page 01-37, Table 1
Analysis: Table 1, operating state of auxiliary heater

Meaning if readout places = 1 x x x x x x x x 1 1
Auxiliary heater switched off because:
1 1
Battery voltage less than 9 V
Alternator faulty
Coolant temperature greater than 70...80 C1) or intake air temperature greater than 5 C
1 1
1
1)
Ignore Ignore
Coolant temperature sender (G62) or intake manifold temperature sender (G72) faulty
Engine start within the last 10 seconds
Models 07.97 - engine speed less than 800 rpm Models 08.97 04.99 - engine speed less than 875 rpm Models 05.99 - engine speed less than 861 rpm
If the intake air temperature at engine start is 5 C, the auxiliary heater is then switched off once the coolant temperature reaches 70 C. If the air temperature is -10 C, however, the auxiliary heater is not switched off until the coolant temperature is 80 C.
Analysis: Table 2, actuation of heating elements

x 1 x 1 Meaning if display places = 1 Actuation of heating elements
Low heating capacity relay (J359), switched on
High heating capacity relay (J360), switched on
Edition 12.00 S00.5111.54.20

01
page 01-37, Table 2 ------------ 01-37 ------------
S ! ! ! A !$ % G ! ! % 0S 3H C ! 8 ! G ! ' H 0 !$ 2 %) ! ! I G % 0S 3 C ! ' ! % H AAG !Q % G ! ! 0 GT 0 GT % 0 3 C 6 8 ! FG %9 % P 8 ! % $ GFG G Q I 2 1 ( H A' " 2 ! %P G G ! ! C FG ( GG R C GT % 0 3 C P 6 1 ( 2 " 1# A # ( C ( A% @ A ! ! !D G# % F& %F& A A % % " # 1 B"# ## )" (# 82 6 ) 0 ! # )# %E A E $ 5F 0 4 F# # 5G (##A 9DA 0#DA 4" 2 ! D# 9#E #& % C 5 # ! ! % 2## " 5 1E 3# 0# 4#F ' $ 9# G FF& 0# ) DE## #D### E F ( 9# P
----------- load cold o.k. 1 o.k. o.k. load cold
------------
01
Specified readouts for injection pump
Read measured value block
Self-diagnosis
o.k.
o.k.
o.k.
Edition 12.00 S00.5111.54.20
OCTAVIA
B G A ` Q Q s B S 8 W 9 G S G S G E A 8 E 8 x 9 G 8 x by e@ G @ B S G G E A 8 E 9 8 p B S 8 F A F S Y sy BE SW 8F We 9 GE S G` S G E A 8 E 8 x 9 G 8 x b9 e9 9 @ @ S S Y I BE B SW S GA S GW E ARE 8B EG 8E xW 9Q G8 8D xA 8 W 9 9 G G E 8 CG @ @ DG p B S 8C EQ W8 ED 8 G 9 E R p B8 SP 8B F9 EE A A Fe x x F RR 8 E c Q BQ B S GG G` E ARE 8wB Eb 8F x@ 9 G 8P xA S S 8 W 9 9 G G E C @ @ c ` c Q e s9 rR B S8 S 8` S EwA 8x EE 8A FG 88 A E A G W RE F 9 A 8 W CW te P8 aW `9 @x c pD9 h BW I SxE 8QF EYD W8s Ex 8A G` 98 R gAv gx QCG b8 Q8 ` ` BR SRH 8W 98 8wx GD@ E 9 RW g S S gs eDC 7ED Ih BD8 9@w G9 E Fe AG 9 8W @wx @Hw8 x 8uUw C xU "E Q !DRs U CHqD E D q $8CU 'DECDus @HXv #WXv %QCDw &AU (EDs B W G ù QC QX b ` yDEv sACDCw Bq B SDHq 8E W@ 9A Gx S GE S G E A 8 E 8 x G 8 x 9 E C @ @ bA e 9 BU SCDCv GDCDw Gs Es As 8D E 9 8 p B Ss 8D F R S Y yDe BH B S 8E WG 9RUuU G S G S GCCUv EE AE 8DuU Eu 8DHq xU GC 8U bADw eh 9 @ DDU S Y S W y@ ssxCH BU U S 8b WA 9A GB S GA S Gf E ARE 8I EF 8Ca xx 9P GC 8E xA 8 W 9 9 G G E A 8 E Cd b8 e9 fR DG wx H @ @ p Bw S 8CC EQ W8 E 8b GC 9 A 8 E W DI pW B Sh 8B FW ER ACH A F8 xf x F R9 8 E E cUUU bG ` y8 sYR BT ` B SQQ 8FV WQ 9xT GGP SX GG S Gc E ARR 8Y EDG 8F xb 9 GHQ 8P xA 8 W G G E C @D @ D wA HE b9 e9 9 h T c Q ` T cU Q b ` a ` s9 rCs B Sqx S 89 S EA 8x EE 8A FDG 88 A8 Es ADs GF W RE F 9 A A 8 W CW ta PA aW `9 @ @ c pE h BW0 RUUC SQD3 8Q1 Eb W8W ExU 8A G8) 98wX RfD@ gA gx QQ b8 Q8 `C `CHwX fE B9 SR 88 9C4 8wx GDu 88 E4 9E AUC As RW C C g U S S dC T Y gU c eDC bv 7ED IQ Bx 9Ww Gb Fa AG 9wW 8D8 EUusv HQ @` @Hqus DG D 5 4 6 DR ADDDvR XCwwX3 x4 "CCCvHUD qUqH2 !4 C CDHu) E HDvU 1 CDDuP uDU U1 CU fs U G U v s DCs $8UQ 'DE T #W %@w3U &AV (EUUQ HqD0
engine idling engine idling
load load cold cold o.k. o.k. 1 1 load cold load cold
Display group for
Display group for
OCTAVIA
Edition 12.00 S00.5111.54.20
Self-diagnosis
o.k.
o.k.
o.k.,
o.k.,
not less
not less
------------
------------
01
re rt g g e e f e j v h d d yd xm t k gGq AGA Ab 77 Wi Eb D 7 EE @W D W S 8 E E @ D @ F @u 9 l S S 7 W @ A H S 7 8 E Y A A S S S 7H 8A 7E F @7 F 7 E RF 97 t7 s A8 AF Hb Ss DBA @EH Dv @S S FD r` FA DCD @8 7D DR D rBi @@ R Dg @ W 7 RF 8 BeeW qQ ter S 7 8 F F F D D ` P I U@ UW Ag H8 f H 77 8F FA 78 rA @@ DE 8C7 H 7CD 7H D 78 R7 rm 79 F rH @ E E B8 BCE sBA 9@ 97 Gx uq I A S @G D @ W D 7 r 7 RD a Q Q b Ui ACD A v S S S W7 D7 7 DCl FH rA FCr @GD F 7 E D W @ sv t7 a p7 Cw CBC AE A SD Dw7 @8B FE W@ DuC7 E@ 8r @E @CU7 @k @ Fi WR DR Eyk 8 W 7 D D @ @ r @ R BCF 9GD tD 9CB CH G8 CR g7 ADE SDQ WD8 DBD7 7Gr 7Gr7 7E9 @ByQ SCl RF@ 7CupB S D@ 7Ce EBer @Cv @ F W RW E @ 8 S 8B@ 7pD 7D r7 DR 7Uj 7v Bo BBe 99 CCDW e@pB efBe Gj 9e herU qC8GCGBk 98Be sQm iRB7 VCC bn pBe e7B a Aj Si 7G7 8e 7r F 77 DvB 8GB @ @e RE RF BBBGCG BRCe dBBB U S S dR a PruGU VQ bB Y cR V P 6D HeBW ACBh 8Cr F` EeC @RCf 8CCCC7 7 Dd BBRz GQ 9I 9Bv Cd CBGBBz GBFR UhuC RCE " Q B B G !r W U !uu A B !Cd F B ! G )Bgu7U 08GG{ 39Cu 2%BT 'e7CC e $v CX # B 4ACT 5BBP 1EBeI (&g9 (Dp (8eX
Read measured value block ----------- or 1
------------
01
Self-diagnosis
block
closed
Edition 12.00 S00.5111.54.20
OCTAVIA
valve
Y P HP F E D i i i R A F R 5 8 2 PI Pb UA Fc DA WF RR D2 Tq AA E I6 YXR ee ` PA HC FpA E7c DYE iH iQR iP RD AP FR RA cCF C9 5cR 8a Y4 Fc E@ Df iF FA pA 7hR 8CE c A 9 ` 7 7 2 s PF PCVR UCf PP HF H6 HF FF1 D2 WCH RRA Da T@ AR X8h2 SA H R E CECD IAR QF A3 @QX 9 8 1 ) &V $ $ " % # Y@ eiD PVRGCe P Hc FFA E6XC DFVc iH iCeD3 iEQdC RQ3BC AQ63 F23Qe RIX R A R F 5VDFB 8hWF q 7 EC C2 f a R3Q AC cC RQ @ b 23 `3 2 2 2 P PVFCG PQA UQD R D A F FCQGqBCB DR WCF RA DA TR AA IQ I 6 YhCQFA E ecFC PRGC P HCe6 FpA E7D DYE iH iWF ihQWQ2 RF A(QF FVH RAd c! Fd RA cX F F CA 5DFB 8hXQ'3C QQGC% q QX YEQe A hF FA F4 EC7 Dc iD R c C6 pAe 7QGb 8VR f d3 FCC RCQ D3 F4 AQ cBB R A XG @ b 3B A33 6X `3 2C 7 2 2 5 PVDF3 Pa UAGC5 P2C PQ HDCBBB H6e HDG FWE3 DR6 WC0E RH DVr3C3QC TQQCC ACeY X8hR DF SCD H EQ R3 A A F E D A CF1 CCA CeD3 IiA QG2 IX Q7 B3 G A2 @ee AVc @ 9 4 63 6 2 8 7 2 2 133 )2 & !C GQC3 C5 $ V3BC Qe $CB3 " C C % %3QC3 #3QQ CCQ C (DBB (p3 02 'D
Edition 12.00 S00.5111.54.20 Read measured value block Read measured value block resistance in cable connection control pump incorrectly set resistance in cable connection control pump incorrectly set piston movement sender at minimum stop piston movement sender at minimum stop resistance in cable connection control pump incorrectly set resistance in cable connection control pump incorrectly set readout readout 1 1 piston movement sender at piston movement sender at
OCTAVIA
Self-diagnosis
readout
readout
replace
replace
replace
replace
stop
stop
------------
------------
01
I 5 8 A 7 I A A 7 AI uI 5DA B8 Bs4 74 AU 7A 5u A@A b4 47 u` I 5A C I HR I 67 yU wT v7 v7 GS @4 4 5 A V v E4 IE I4 IDV 7E I A 4@A 4b A4 48 bU 7A 44 A8 b7 5S B 47 I 5i BA 5 A 7 7 7 7 C B 7 C B B A 99T 9b 9b 9A T 6A `5 @ 8 I 4 A 4 C 7 7 A A U T R S V q g I I I A 7 4 A 4 4 A 4 b 4 5 C V vV V EC Eh 6 E I4 4s9@u AA I 5A B 4R 54 Bb 54 I A9D7 bC 4V 5b 79 7 4 4 4 C 7 C B A A 9u T5 65 DC DH @B EH 7uG A9 uu 5A B87 Bbp 7EA AT 7 5g A7 bxG 44 u4 I 5Db C4 I H97 I 59 7 4 A 7 4 9U 64` yA wG v8 v5 GA @7Q @65 DA U DB `B I4 I@` I9 Au 7`S 47 A 7 b4 Ab 4v 4A A@db 44 7 b A 5 9D5 9V U T h q @9Dw dA g 7 U T U R T V E I I I A7 I 74 4u A4 7C A6 4 A 4 b 7 A b 4 f WC w9 Vs I7 ID4 IED A4H 74@@ 4@b99 AvP 7sb b9Cs A8Q 4A 4c@6 A4 4C b9b 7A 7sA A4 7u b5 5C 5 7du 7A 95 Xs @4@9 `q WddP V@ 2@9 84 C9Q@ A9Ps Bg 44 6`B #@Qs #P`@ H@@H "9@D@ b@ rH 4 ! P T S h i 8%rdH@D A7 7b I AH@H I I 49 7 A 4 A 999@ 7 5 B B g5 8 E9 7E999d AbD`s 7S 55 A bxU 47 u5 59D99 Cb Hb@ I I I 5 7 4 A 7 4 A b 7 9s8 9H yA@ VU vS VC DA @h U ` g 4 5 A 7 Vd@s v V E4 E 8 I A 7 7 7 7 C B 7 C B C B A I4PH IS9 I`R 74Q9 IT A@7 45PH 4bQ A4Q 48P b8P 7AP 4i Ag bb 57 B4 44 5R BA 5 A b6 9Ad 9b 9b 9 T@9 6A `@r D4 @9 I C 7 A u A 2 A U9 T R S q g`P I I I 4P 5P C A 7 4 A 7 A 4 A 4 b V! vS V2 EA E9V U E 8 4DS 59 7v 7 I4 4s9@5 A@D7 I 5G B 4A 54 Bdb 54 I AA b5 4 4 4 C 7 C B B A A 97 9u T5 65 DC DT @$ Db x 6 Eb 7u9` A98` uu% 5A@9 B8aY B3 76 AT 7! bxG 4u u4 5Du Cb HEH 5 A5 I I I 59 7 4 A 7 b 4 4 4 7 9U 64@ @7Q @6 DA yA wG vHb vC GA U `H Dw g p I9SH IGP IG A7C 7ÈG 47G A4F 7I b4P AB 4s 44 AR 4F b 7 b 5 A 5 94 9H @9H dA UQ TQ h S q Q 2 g 7F U T U R T S i S E I I I Ab I 7`@ 4D9 A@ 7 b9 A 4 A 4 b 7 5 A b 4 99 f @G e A5 7rH 5@` 4 C b9u bd1 B 99s `' 8C I70 ID@7 I96 Av( 7s# A8 47 4c@%P A4 4C b9b 7 7Q9 ba`9 A44 7`4) 4@h bb@9 A9Q 7d9 594 5 7@H 5d AA H9 9@4 9Cs 9@9s 96 @79 `7 XB @DB@ d79 I W U T R V U& T S R F F 3A 2@ 8@Q E9G A9PQ 7@PG 54 4 5P9PG CPH@ B@g 6`C @C @`9d 6@PddP DD@u ( # ' ) ) 1 s #@9@@PH # 9ddb @S@ "@ b@@0& !9QP @9 s 4 $@@G `H@D` !F PQ ! @DC %rY %`s %HP
Read measured value block Read measured value block ------------
------------
01
engine idling
engine idling
cold
Self-diagnosis
cold
cold
valve
valve
valve
valve
not less than +80 C)
not less than +85 C)
blocked
blocked
valve
valve
Edition 12.00 S00.5111.54.20
OCTAVIA
W e F I E W I P B Q X Fr Sr f W CHD W IW W W CF IpP EHB BV IE EI rI I B B I B B r G W RB t H C Q E FI WrB WS WVI IEr BGRB B ID BB rpVP E` BE rX P WI B Er IHB rGI W QB rI Q W It E B E r r B B r E GW Ge GE GI G u E B I C E r I B w SD W W W CB QB IE Ip PGP Ep BV I rG I I B r E B Q BB IE CB B E` rX VB yI GI DB D RE HS tHf xE xD aqd sEX W W W IG Ep E r I B I B r r W C B E G v u EQ CHT BG r FGI WB WRr Wr IrB EIG IC Bb BsHD Ic BpE rHI EH EGB rGHr IBx EpEx BBf rx IB EtVG CH CD EB C rr I GQ GGHI G HE hP HC tE 9Y W gY e d b f e c AIH 9V SGHT F` Y CpGT Q9Y PXY EQ CT Ba IpB DQY ( 5 &X (qppHHH# $Bi RIHHHGH! EHHX B6V IGGT $I !BRY IQ !r` d E !Gp9 $GRHc !rU HHX RH E 8 'U rH !Gtt U $ tHH6 pH !H )THGHa 1IVH"Y D PGR GHPT 3B!7 0EpV 2IGtG 4IHVH r #p % #a b
Edition 12.00 S00.5111.54.20
Notes:
for
OCTAVIA
Accelerate the vehicle at full throttle for the test.
o.k.
o.k.
o.k.
Self-diagnosis
block
valve
------------
valve
------------
01
H Q G ` Q G S Q `Pd D` ` QQ ED G` Qg GPf DTYG DID uu i uu QV QD G ` YQ D Q Y FQ H H ` ` ` DH G ED Sg GPu QR D ES R RD GS QPU GH EPI QPD uu E iS hD hU WR F G ` ` ` D G G D VD hI V Uu UQ Q HS ` QuQ ED DIH EU R ED QI uD È Du GQ Q uD ` SI uTD S ` Q G Q G Q u G IS ID I fD F` PQ Ps Q E Q UQ QGI DG DD QYD ED Dg GD uD ` ` ` E SG QG Q RI G YD G u Q G D D S TD yQ IE IIQ D F ctG vQ FD TQ TG PU ` E D ` ` ` Q G u D D u G u V YQ U DQ ED SF ÌG ù `sR QD GY DR QG GQ uQ ` QH DYTs DD Qu DQ uD GI DR uR Q E RG D E E Q u ID f F sQ PQ E R R G G F TuY D HU U DQ D EPG Su EU Qh ` ` ` E QD GsPTG D QI GI uI Q D Q D G IF Iu IR iTQ hRY hPS WI g TGs P su TD Ps wu Pww I DbPT QD EwTI DI GPW uF QF Y x b GbP yPI pwh Ib a W HS ù `TwGb `Pus QDD GsDsb DDYb Quwu GGQ uQD QG DQ DvPIITI QIPtsa De uPR GT GIu QIIc GsPPwP u Ei EPI GI E u Q IusI IS IP IIPQ qR PuD wG PG ss s AY pX g f d iW g f e h a e a CQP UAPPb HV PPwPbb SPPIPPD Gsbb EITbW DW QW FsS FPW PP ' ' " 4 9 8I 8P# @ 51 8 6 5c $EY 'I &R" wVI3 "b PITPP$Pr uP &w2 2 b ITPY! I` %bT P b bS QI2 A0 P YV )QY h7PPc (GPTIsb " #7V d
Read measured value block -----------
------------
01
Notes:
at
test in
Self-diagnosis
valve blocked
leaks
valve
not less
block
+80
valve
Edition 12.00 S00.5111.54.20
OCTAVIA
engine
E H D W H D P FA WGE AW W HA BD DW HH Dd AGr A r GR rA HS HA D W VP A H V Cr E E W W W AE H BA Pd DA HGc C BI IQV IP DH Hr DH BGF Hr r B fP eA eR TI CA D W W W A D D SA eF S RQr RH H EH WA HrH BA AFH BR IGA BA HH rA WB AA DH H rf W PF ra P W H D H D r A r FP FA F cD CW Qr Gp w x H r H y D uH RH HDD ADF AA HE BA Ad DA rA W W W BQA PD HP H IF D VA D r H D A A P H FB B CA QD GD yAV ` sH R W W W H D r A A r D r W B H A S VH R W WA WpF AH qGD BA PC HVA DP AI HD Dr rH W HH AVQF AA Hr AH rA DI AI H rp B Ir B B H r FA c C pH G B I I D D C A A EFD R BR He W W W B HpV DF8 Av HI Dt rF H A H A D AFD r Be Pr FC Fr FI fQH eFFE eGVR TGQD d QDGtF G QA Gp tF G w x tpC AYGv HA BGtF AF rC HF VGT y u u Y DYGF gte vpG X T EFF Wr WQtAY WGrGp HAA DpApGY AAVY HHF DDH rHA HDY AH AsGFFQ` H Ab rGI DGQ DFr HFT DGpr rqptG BFGA BG DGY B D H FAG FP FP FFGGFGv h GrA tD Gpr ppG p 8T gtGYGGY dY c a fY d c b X X @HG 8V RFI EGS PGVX IfY DpS BFQYT AT CpP CGT ' ' 5 7U 4` BQG tQGGYP QHGV tS "D! 0 ! r6 7Y0 FGQFQ e Q1 FW GG! 2 3 #HbV H VF) F( &FGiFG DYF rQFpGG`Y $HY %D0 S a
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required). Accelerate the vehicle at full throttle for the test.
Edition 12.00 S00.5111.54.20 Read measured value block
Display group
OCTAVIA
Notes:
at full
test in
Self-diagnosis
or
gear
valve blocked
leaks
valve
not less
block
------------
valve
engine
------------
01
Specified readouts for engine idling
Display group 002, engine idling (engine warm, coolant temperature not less than +85 C)
Read measured value block 900 rpm 0.0 % 2 K Readout in display
Engine speed
Analysis: display of engine operating state

x x 1 x 1 Meaning if display places = 1 AC signal
v o.k.: (idling speed switch closed)
Idling speed increased: if AC switched on switch off air conditioning test brake if accelerator and brake detected pedal switch if coolant auxiliary heater switched on warm up engine
------------ 01-46 ------------

010 88.4 C Accelerator pedal position 0.0 % o.k. > 0.0 % Accelerator pedal position sender incorrectly set or faulty page 01-38; display group 001 Engine operating state Coolant temperature 85...100 C o.k. < 85 C: warm up engine Table of engine operating state, page 01-46 page 23-47 Engine operating state switch off air conditioning Edition 12.00 S00.5111.54.20
01
Self-diagnosis
OCTAVIA
OCTAVIA
Self-diagnosis
01
Display group 013, engine idling (engine warm, coolant temperature not less than +85 C) for models 07.97 The fuel injection system features a smooth idling control. It is able to detect differences in performance between the individual cylinders (parts tolerances, injector flow, compression, etc.) and to compensate for these by selective metering of the quantity of fuel injected in the idling speed range.
- ... mg/H: The relevant cylinder is stronger in performance than cylinder 3 and is therefore supplied with less fuel.
+... mg/H: The relevant cylinder has a weaker performance than cylinder 3 and is therefore supplied with more fuel.
What is shown in the measured value block is the variation of the injected quantity of the individual cylinders in comparison to cylinder 3, which is necessary to achieve smooth engine idling.
If the control unit has detected a variation, the cylinder in question is immediately supplied with a greater or lesser injected quantity until the engine is again running smoothly.
Such differences are detected in the idling speed range on the basis of the signal supplied by the engine speed sender, which supplies four signals for each crankshaft revolution to the control unit. If the signals are received in the same rhythm, all the cylinders are performing the same work. If one cylinder has a weaker performance, the crankshaft requires a longer time for the next half crankshaft revolution. In contrast, a cylinder with a stronger performance accelerates the crankshaft to such an extent that it requires a shorter time.
Read measured value block 0.82 mg/H -0.12 mg/H
0.49 mg/H
13
Variation of injected quantity of cylinders 4, 2, 1 to cylinder 3 -1.5 mg/H...+1.5 mg/H o.k. All display blocks are too large: cylinder 3 strong All display blocks are too small: cylinder 3 weak Variation of injected quantity of cylinder 1 to cylinder 3 -1.5 mg/H...+1.5 mg/H o.k. > +1.5 mg/H: cylinder 1 weak < -1.5 mg/H: cylinder 1 strong
Variation of injected quantity of cylinder 4 to cylinder 3 -1.5 mg/H...+1.5 mg/H o.k. > +1.5 mg/H: cylinder 4 weak < -1.5 mg/H: cylinder 4 strong
Variation of injected quantity of cylinder 2 to cylinder 3 -1.5 mg/H...+1.5 mg/H o.k. > +1.5 mg/H: cylinder 2 weak < -1.5 mg/H: cylinder 2 strong
Edition 12.00 S00.5111.54.20
------------

------------
K Readout in display No readout
01
If the control unit has detected a variation, the cylinder in question is immediately supplied with a greater or lesser injected quantity until the engine is again running smoothly. - ... The relevant cylinder has a weaker performance than cylinder The relevant cylinder is stronger in performance than cylinder
in display
Such differences are detected in the idling speed range on the basis of the signal supplied by the engine speed sender, which supplies four signals for each crankshaft revolution to the control unit. If the signals are received in the same rhythm, all the cylinders are performing the same work. If one cylinder has a weaker performance, the crankshaft requires a longer time for the next half crankshaft revolution. In contrast, a cylinder with a stronger performance accelerates the crankshaft to such an extent that it requires a shorter time.
The fuel injection system features a smooth idling control. It is able to detect differences in performance between the individual cylinders (parts tolerances, injector flow, compression, etc.) and to compensate for these by selective metering of the quantity of fuel injected in the idling speed range.
------------
a d a d a a b d d W q a d ` W ` i a ` d ` a a b h d d W ` W ` ` q a b d S W ` i a b h d S W ` a a b b h d d W ` W ` SW q e a b d fp W ` c i` p` ab bXc h` db fb WXc ì c Xh XX` Xc e aXXecc bh ah bcX hXXXX dRX db WcXe `cW Wq `c cb fRXXc eX acX ac a a dpY dX è R` d WW ` R W f UpcXcpX pE IpXXXXX EcXee DW D CP FW F 7 BbpX 7 BRXe 0 !49X #d !8 S g %bc26 G @ %We6 #QA %bA6 3 8 'b $R5 $@ $ $C VIHXc &b ("1) 9
Self-diagnosis
OCTAVIA
models
engine idling (engine
not less
C)
and is therefore supplied with more fuel. and is therefore supplied with less fuel.
measured value
Idling controller - injected quantity cylinder o.k. cylinder weak cylinder strong
------------
Edition 12.00 S00.5111.54.20
p s i ` pY s y i a i i a V ` Y ` y h a ye ai sV ay ic sV ac p yt i ` y Y a e uuf i c q w gd yi pd ` y i p uY s fy W Va Vi Wv a y yut a si uj yi V a s i y u ` a e c Y We V V Wup i W yy a sd a yp qy s a s y t a p ` y y q V ` a c Y W W a ` pst av pt yi iua sy yi ta v y y p u c q YY xy by i v y i t V t p gwwwi Y d Y r v v iy pY sqwy sq ti pu ia sxy a sl s y qW p qe uV uu uV h bq w V W ` ` e c c gw f d Y Y V @ @&uw6k @q 2wi 7a %quw 9( 'X 7bbbu 8% 7wa 1q1 1u '2 A 0uU ' 0 1 8y$ 'w% 8$ ) 8 7 Du' Bi B4 Fy3 BWw H" Ci7 E0y Gr7 Ivqw1 3 www !S&# uwR 5ww ) b b0 TP b 5 # S& q 0 bwu wQ
Edition 12.00 S00.5111.54.20 900 rpm Read measured value block
OCTAVIA
engine idling
speed
air mass requested by control unit
too cold warm up quantity too temperature very
gas
display
air mass air mass in display block
Self-diagnosis
air in intake area inspect intake system recirculation
ratio
recirculation blip substitute value
readouts injection pump no correction possible
not less
recirculation valve
leaks
------------
ault memory
------------
01
S G X F G V F G Q V V f q w 7 V F 8 F 7 u8 iX SVQ 7 V6 8F PV f 8 F PX 88 F@ PS 8@ G V6 Ff qV q6 BY R7 RRQ 6d 6 @ Hd x7 TY cX 3 3 4 i V 8 P P B 4e 36 3Y 4uG iV S VR8 8W PS f VuV Y6 P 8 Y P F V Ra R3 4 ` a V F F VG GTA 7 V3 F G 8 F RQ RF RP s d X yh x3 w VV FV 8V FP VP 7H PTT V F 8 q s v 7 8 a @ 6 4q 3q8 3B 4uF W iB S VG YH VP 8W PV f8 PH 8 P Y V Y Q Rb s X q GX 7 qYTQ V V p H d 3 7 8 @ 4Y e `F `s GY V V f Q Y d bqF S V F Q d `f `ì `` G` BF a` Dq bR8 6H Ci Iq Sd Sf PV 8g Y8 Pd VY YTF Gd Fv WH8 G6 PHTV Ps Qb GF Fi RF RRq XYc HRF Eic UTV T8 HRTi 9RH 3 4 7 7 8 BR @ @ DxRT Ci A 6 3Ti 2 R9`TTT !PTh990' 6Tci T3 #x8 HHTTc ` Rxh5 #9RT !T #h1 H` i V 6 %RtTT( "3 "4 "T9xTR "9) Vi $F9H &R4T
Read measured value block 900 rpm
------------
01
models
------------
engine idling (engine
speed
air mass requested by control unit
too cold up quantity too temperature very
display
mass meter
air mass air mass in display block
too cold
Self-diagnosis
air in intake area inspect intake system recirculation
ratio
blip recirculation t p substitute value
readouts pump no correction possible
up
not less
recirculation valve
C)
leaks
Edition 12.00 S00.5111.54.20
OCTAVIA
memory
OCTAVIA
Notes:
c H X c w c Tc QT H pS v P u C BQ W s Q T s S t Xt YF `r cv cg TSQ QTW QRVU hU hf igT f` Te ed eW pT bVS Wp Sr T S Q Q XGUG YfRR PQ `C H B H H P C G H 9I 43 (D (dd3 (y 3b6R 4r 8Edb &a 4g 4 $G 4 ) ( 4 & 4 4 ' " B5 ETE Ex DaV qD 4 3 1 7& 73 7 @( #a) 0 bdC! Awb" A4 d4 AS C & U 0 E% e F d' UG d2RE ( b# a $ b
Self-diagnosis
01
K Readout in display temperature open circuit in substitute value
coolant temperature sender a uel temperature is s
as a
temperature open circuit in
readout
temperature intake open circuit in a constant
temperature sender is as a substitute value
temperature sender a constant is
as a substitute value
It is not possible to state specifications for the temperatures.
If the engine is cooled down, the temperature readouts for fuel, intake manifold and coolant are by necessity approximately identical with the ambient temperature. If one of the readout differs significantly, it is then necessary to test the appropriate sensor.
Edition 12.00 S00.5111.54.20
------------
------------
01
Specified readouts for

for
Notes:
Read measured value block rpm K Readout in display
------------
dt dh VW Yh `v xU auT xus i h ca T V Tq sq ah fh fh xa ` a t V T X r xU au ` wr T XuyX sY s `c `q aYw hh ri xt h fu ap f hp t p p cY` Vt Ts Tq bYh q f d s sh hv aph t x h a a puc UxW Th Tf Uh w yyW yx xW yh hc apuph tuR h fx hu f if a st pt Tr Tfuh Ut ux ` a ci V T Y Y xi ù aY cY U V T xh f t rh hpV hgpp hga iX p yvf uv wf qf `Y ` a a d d cu Vp c TY Rpy Y I Q @pu! B"Tg 7pYV #si 'biYgU 7` 4fu" (W 48Yp !B #pte 4h 7ppI 4i# 'U 'bp4 #1b! &rp Af &h %X #% 4pb ' &a ' 4 # ' 4 & ( ( CfT Dc& 17p 1s 1s 1&b 1 1 Fwbpbp$ 3vh 0fW E G1teuH "f' 3# 6 90 6 3 ) 52" 6 &1" ) 1"P ' T b"Y Yb e1 & 1
Self-diagnosis
OCTAVIA
limit on
basis
detected air mass
- detected air mass recirculation at control on basis
speed
test air mass meter load
speed too or too increased as a result pedal
speed
rpm
pedal not p
accelerator pedal position sender
incorrectly set or
------------
Edition 12.00 S00.5111.54.20
OCTAVIA
Display group Notes:
R C D Ff f GV q IEV ia Q B aT F GV Tb TI fEa I P A W F B B B p F VgD TV Gf TEb VV Vq Vq tA Wd fG qt Gp v YY eA gEcD A ` F f G I EI EucR ET Eb aV a d FEt VT `V fW VA T Gi Ti VB f` T b ` V vfV vF vyG XG PXY Af Ad ccY Y g ue V VccyQ GV bT tG VcV qV bG Ga V w q W w Xx Xq Qt AHv Aa Q` sV uEeT aB W Vqb Gbs bqh tVd TV Vcq Tc WT vDb Xb AXV ATcV QecX gV cf p Fh GcE IW P A E Eb hy FXEX GH IW iB AT PE AE HW dV fVh VXB T bu VV VG TT WE XXB XC XQ eTg YHE gvX FXEc F F G G RE IsX I I AE & & 0 ' 1 7B 6B 6E 85 3 3X aHXc E aEX `XESc "g4) ! RB 6HS YU XP XcHD cXU GXA cVC X2 #s9! C5X h! E( %E fA) VSc qH) $qW D HU UH cQ
Self-diagnosis or gear
01
at full
(road test in
not less
engine
limit on
basis
detected air mass
- detected air mass control on speed too
basis
test air mass meter recirculation t speed
or too
speed
pedal
increased as a result
speed
rpm
pedal not p
incorrectly set or
Edition 12.00 S00.5111.54.20
------------
------------
01
Notes:
------------
x U Y F I G B d Ii iHD P` ie w t ` RHB rHd TY B dW g PY We WR iD I W e R T D I w E E E G s I YY WpP Pi WHG YY Ye Yt wt `b iP tg PY bY hD hs R D c B I R r T T d dY YD W Pr Wa YE ic W e Y IHw YW cff` iU a aP p fG P ffb b xha Y Yb PpQc eW wP YY ti e` Pd Y Y ` a aY aft Tha Dt Dd` Tc xfT D dE WY YY W `W Yte Pi et wYF tP ae yDe DWfY TvYW pi ft fD DaY s IqH PfHH U R` D G ig IVH PqHa UH R` rE EXY DH gY iYq YY W ex cfQHQ YW YP WW à aHE av aT hW baH pT G Iap I I P Ua RaE R R DH QVH E vQf @fD ) ! # 4 7 A 8 &dQa &Hf )afHF (dHa# Ya p9H !gHQ5 ab5 UX5 !A (f! !H S fD QHX! Pa! QG ' H !Qf6 H a E V 0vB3 f qHP 2e ) tq$ 1af #" %X $ # T
Self-diagnosis
OCTAVIA
at
test in
not less
engine
limit on
basis
detected air mass
- detected air mass control on speed too
basis
test air mass meter recirculation speed
or too
speed
pedal
increased as a result
speed
rpm
pedal not p
incorrectly set or
------------
Edition 12.00 S00.5111.54.20
9 9 R R S 9 T @ B @ S 9 9 9 v x P @ H G S S H F @ 6 6 6 v 6 s v S S V S 9 H ` G H 5 59 5B fB P C CH Pd B F 9 H 9S TA @F HW HV B9 T6 @a HF GG aH WR Q@ 6@ 69 A9 I` 9 F @ F B w c@ C P BF 9 9 9 G G @ 9 a WF dT 66 sG u 6@ Q 9D @9 H 9 G hb9 tC s9 fs CS P6@ P@D 9G Fv 9Da Fd BEY G6 BG HpD @W Ga 9a Hf B9 9 a` 9 ` ` aIa @aCh 9TaD 99v GBf B9F FcF `t ``H arx h9 DS DF DEB gÌF i` A9 p@DA ID5P AY Y Ix ET 9@ 9T H9 9@ G` Ga By F9 99 H 9 ` ` af AT AW AD Y eb 5DEr XF 66 6G 5cB cAD cD bEDI` BBD Fa9 B`p BDD@ H9 @C GI6 HH BG @T 9T 9C À àI aT A@ E IB Xvc 6BED dGca 6cB Yfa 5D 5 S W Xa 6ca 6 6 8caDf 5cIbf Pa9 C9 DDa @HUEE HaF GD9 B9 @e 9aaED FbW AAf 6af E ( (apDÙ #@aE y v Ha "" #BU vET cIv C6 #aA rI9 IR 'V EE 6Q a # 6 D )95E 1CDIG @ f&EaID Qa 36bGD 0@Q B@ 2RDIEG 4Aa aDER % $! "Eb h
Edition 12.00 S00.5111.54.20
Notes:
for
OCTAVIA
07.97
mbar
mass
less
mbar
mass
or more
Self-diagnosis
block
mbar
------------
or
------------
01
Y R by bp QH HX I c U I c Q H U b H I W f e f a a b H c I Q b H p P Y I W V i a b W H H W H U U V H H p c V E E E P P H b e b b c e U b H W i Q U V uTV R Y R I cH I W Vp H I Q XE E aV D DH DW uD Rf YI R RI YSQ IX U Q H i H W Hb ci IU WI WQ QH cpH IpH WQ VH pW fpH xV Ec EP P H U I H U Q ri rp R Y QI H H W V V b H I U Q sc EE Ù H EI EQ uE H V HE I W wXE S R aS yaS RHQ YEi YIW IpRt HcpV HcU VHuS QHc UrSi ipVU icS pES HV U HSR Us QI V WySU ISH Hh WY QP IH HQ H i i pu p w Sui SQuI SSH vQ xH X Tc P XSDP P` h HH Hs WQ HW Vi VH Q UQ IW HR WH QS` Hy Hr pQ i i pu p Pc PT PI h DI gTSX EV EE DrQ r rR QSS UpH QDq QH Wc I VX Wf QH Ic HE HU irSp ipy pc pV SSpTXuS gRTTSS ERr siTP ErSI hud TH XQ Dqp D f gp Erd E GVTT DrXqu YpH RU SSXp WpU VTVSS QVu IP HH UTpTSpTS XqW Pp PVu ETpu ' ' !T B Aq0 AXd Ci 8@ A 9S 8Tp $I $6 'T & QTpd qpy I Th E Ha &Sp" TSXXpTc p e Sy 4 X@p %q X0 S a S E (QV5 Ip H3 V qS0 p` 2Vb 0P`5 tSSE )HD5 1wSp0 TTE !! # "T ! Xi7
Read measured value block -----------
------------
01
Notes:
010 at
mbar
mass
mbar
or
test in
mass
value
Self-diagnosis
block
mbar
not less
Edition 12.00 S00.5111.54.20
OCTAVIA
or
engine
5 PD C Sa S9 B 9 @ T F @ T B 9 F 9 T @ H 9 R R s C S 9 T @ B @ S 9 a v x @ H G R v x S H 9 9 H 9 F G 9 9 H T G B 6 6 6 R A A ID S V S T V F S 9 H ` B G f9 C P C T9 @B H G @ 9 T @ B ` s` sH RG sf v 5 59 5aF fS C@ PC C@ PD C 9S TA @F HW HB B9 T9 @a9 HC G` aH 9 @ B F B 9 ` 9 H 6B W 6F 6A AG I6 9 F @ 9 F B w c` ca C B@ 9 9 H G G ` 9 @ @ F 9 B WEB WI` dT 6a sG 6@ u v f6 9 G 99 @9 H hDf D tC R sB f` C9B Ps9 P@pF @a6D 9Taf 9TQ G9a B9v FcF à`G ``F 9G FpDr 9v Fd B@ GaG B HbD arx @DD 99 H B9 9 aP 9 ` ` af a hV DS Dy D6 DA gBD i@ p@DaD ID5P Ix ET A AT YEIf I6 99 9d` H9 9EY Gv GDaG By FEpDF 9Y HaD Bb@ @H 9@ 9e aB ` ` a6 AT AE A9 YC 5F bT XaDba 69 66 5cB cIb cB BvDDD F5ED B5a BGU HQ @C GIv 9IaDp H9 BEDa @G 96 9c` `cD à aG DDab dGEA XCcU 6ErEED 6cB A@ Yaa E9 Ir9 IT 5 5 S W V Xa 6cIb 6DIa 6 Q 6 Q 8GEE 5af Pa9 C9 HaF GDF BIGED @A 99 FWf DH IW AAD AT 6Eaf E EfIUcDf 3 E # D ( % $ 4R 1# @H G apE6U BEa& b2' & PE' 4 ErDIIaET v 5 ) 0 @a & "GapDD6 e& !QaD' ER
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required). Accelerate the vehicle at full throttle for the test.
Edition 12.00 S00.5111.54.20 Read measured value block mbar mass mbar or
Display group 010 at full
OCTAVIA
Notes:
test in
mass
value
Self-diagnosis
or
block
gear coolant t
mbar
not less
------------
+80
or
engine
------------
01
01
Self-diagnosis
OCTAVIA
Specified readouts for charge pressure control
Display group 011 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +85 C) for models 07.97 Notes: Accelerate the vehicle at full throttle for the test.
Read measured value block 3340 rpm 1830 mbar 11 K Readout in display
1850 mbar
68 %
Engine speed 2800...3200 rpm o.k.
Specified charge pressure requested by control unit 1800...2050 mbar o.k. > 2050 mbar charge pressure increased by tuning
Momentary charge pressure as specified charge pressure in display block 2 (tolerance 100 mbar) o.k. insufficient charge pressure: test, page 23-22 - No charge pressure control excessive charge pressure: - Pressure hose of charge pressure control dropped off or blocked, solenoid test charge pressure, page 23-22 valve -N75 jamming - Linkage at turbocharger rusted tight, pressure unit faulty test charge pressure, page 23-22
------------ 01-58 ------------

On/off ratio (actuation) of charge pressure control solenoid valve -N75 Edition 12.00 S00.5111.54.20
OCTAVIA
Display group 011 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80 C, engine speed 2900...3100 rpm) for models 08.97 04.99 Notes: Accelerate the vehicle at full throttle for the test.
Read measured value block rpm mbar 11 K Readout in display ratio
Edition 12.00 S00.5111.54.20
$ ) ) ! # ' ! 0 C ) $0 8) !0 )R ! 0)0 ) !(Y "( (R #0 ' T ' 1" $C 09 7 ) 7 !0 DQ$ 0D 00 DX 0#' C0 )D C$ !C "5 2 90 9) #(0 9@! ' PP @9 $ ' 0! ' "$ 0 ! 0 " 0 C C C R) 59 ' Q" I $ E( 0 0 D C ) C ! 0 " 0 0 C C ( ( 10 0(D )) !" D(S 0W C 0 ) ! #" #4 9" 9$ @G 9@ 2 ' $` 0 0 D 0 C C ! ( ' B 3( 3 A0 A4 ! 0 0 )@" !( ( #0 #U '0 9' '" %V %) 5 9 %(( 8 0( )3 ! " 7 ! 0 ' 6 3 3( 3 3 ( ( 1 ( 53 4 3 3 2 $%(3 ! !#@ "9 0H%3 )53 !(113 %(( "C 3 ( ) #13 #4 1 '53 &%1## E % ( 0 3 3 %% 3%%%
Self-diagnosis
01
mbar
pressure control solenoid valve
pressure mbar must mbar icient pressure control
display block
tol erance
solenoid valve at
pressure control dropped test rusted pressure unit
or
test
speed
pressure by control unit mbar mbar pressure increased by rpm
------------
------------
01
Notes:
Read measured value block rpm mbar 11 K Readout in display ratio
------------
R X c P P d c U W w U X x w @ X rU Ud cd deX cc Us VU bc ah a aWc Xd q q dd cd Uc xU dWA dF xC dA ww c wA ba bi b F E sd sX @x stP ad R td dVV RP VSa d d R w a a c is SV X d d x w c w U d V d d w b ed dbx cc Ub xa d wF d c U R Wb sR sb @t stb f Xb X dA d d c w U V w P a C R A A ud uh PC dA dC ct Ug R Wd F W F ad sU aV YS Ys i A s s A D r d c U V q U P a p g RV Fb Fb Hb ib hP Bg Fe Eg fe XbW RYVg P@ RF VTSd UWtS Vs dSyA cig UWA Rg bR Pc WD Wh Ieg aiS `YeWP YC Qg G@ C HYgYYY Dg A D D g & ! 6 8 8 54 #U #g1 &bg %Ugg2 xY v a1 YV) C be3 % ygb F C bA b 1 $Sg7 e w0 E bYYA S wS d g SA (U1 &2 'f2 " ! bgB
Self-diagnosis
OCTAVIA
011 at
test in
not less
+80
engine
mbar
pressure control solenoid valve
pressure mbar must mbar icient pressure control o c
display block
tolerance
ressure valve at
pressure control dropped o or test rusted pressure unit
solenoid
test
speed
pressure by control unit mbar mbar pressure increased by rpm
------------
Edition 12.00 S00.5111.54.20
OCTAVIA
Fuel Preparation/Fuel Injection
23
Servicing diesel direct injection system

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

Pay careful attention to the following 5 rules for cleanliness when carrying out work on the fuel supply/fuel injection system: Thoroughly clean connection points and the surrounding area before disconnecting. Place removed parts down on a clean surface and cover over. Do not use fluffing cloths! Carefully cover over or seal opened components if repairs are not carried out immediately. Install only clean parts: Do not remove replacement parts from their wrapping until just before installing. Do not use parts which have been stored unwrapped (e.g. in tool boxes etc.). If the system is opened: Avoid working with compressed air, if possible. Avoid moving the vehicle, if possible. In addition, ensure that no diesel fuel flows onto the coolant hoses. If this happens, it is then necessary to clean the hoses again without delay. Replace any hoses which have suffered damage.
Edition 05.97 S00.5111.51.20
------------ 23-1 ------------
23
Fuel Formation / Fuel Injection
OCTAVIA
Summary of fitting locations 07.97
Components A to E are not shown on the summary illustration. A - Relay for diesel direct injection system (J322) Electrical centre page 23-2.1, Fig. 1 B - Glow plug relay (J52) Electrical centre page 23-2.1, Fig. 1 C - Accelerator pedal position sender (G79) In footwell at accelerator pedal page 23-6
------------ 23-2 ------------
D - Brake light switch (F) and brake pedal switch (F47) Combined in a housing In footwell at brake pedal page 23-2.1, Fig. 1 E - Clutch pedal switch (F36) In footwell at clutch pedal page 23-2.1, Fig. 1
Edition 03.98 S00.5111.52.20
OCTAVIA
Fuel Formation / Fuel Injection 11 - Plug connection 2-pin For needle lift sender (G80) 12 - Plug connection 3-pin For engine speed sender (G28) 13 - Plug connection 10-pin For fuel temperature sender (G81) For quantity adjuster (N146) For modulating piston movement sender (G149) For commencement of injection valve (N108) For fuel cut-off valve (N109) 14 - Commencement of injection valve (N108) 15 - Fuel cut-off valve (N109) 16 - Fuel metering control of injection pump With fuel temperature sender With quantity adjuster (N146) With modulating piston movement sender (G149) 17 - Intake manifold pressure sender (G71) and intake manifold temperature sender (G72)
23
1 - Mechanical exhaust gas recirculation valve 2 - Injection nozzle with needle lift sender (G80) 3 - Diesel direct injection system control unit (J248) With altitude sender (F96) 4 - Electromagnetic EGR valve (N18) 5 - Charge pressure control solenoid valve (N75) 6 - Air mass meter (G70) 7 - High heating capacity relay (J360) Only for models with optional equipment 8 - Low heating capacity relay (J359) Only for models with optional equipment 9 - Coolant temperature sender (G62) 10 - Engine speed sender (G28)
K Fig. 1
Components in footwell
1 - Glow plug relay (J52) 2 - Diesel direct injection system relay (J322) 3 - Clutch pedal switch (F36) 4 - Brake light switch (F) and brake pedal switch (F47)
Edition 03.98 S00.5111.52.20
------------ 23-2.1 ------------
Overview of fitting locations 08.97 07.00
23
Fuel Formation/Fuel Injection
OCTAVIA
Components A to E are not shown in the illustration. A - Diesel direct injection system relay (J322) electrical centre page 23-3, Fig. 2 B - Glow plug relay (J52) electrical centre page 23-3, Fig. 2 C - Accelerator pedal position sender (G79) in footwell at accelerator pedal page 23-6
------------ 23-2.2 ------------
D - Brake light switch (F) and brake pedal switch (F47) combined in a housing in footwell at brake pedal page 23-3, Fig. 2 E - Clutch pedal switch (F36) in footwell at clutch pedal page 23-3, Fig. 2
Edition 12.00 S00.5111.54.20
OCTAVIA
Fuel Formation / Fuel Injection 11 - Engine speed sender (G28) 12 - Plug connection 2-pin For needle lift sender (G80) 13 - Plug connection 3-pin For engine speed sender (G28) 14 - Plug connection 10-pin For fuel temperature sender (G81) For quantity adjuster (N146) For modulating piston movement sender (G149) For commencement of injection valve (N108) For fuel cut-off valve (N109) 15 - Commencement of injection valve (N108) 16 - Fuel cut-off valve (N109) 17 - Fuel metering control of injection pump With fuel temperature sender With quantity adjuster (N146) With modulating piston movement sender (G149) 18 - Intake manifold pressure sender (G71) and intake manifold temperature sender (G72)
23
1 - Intake fitting With mechanical exhaust gas recirculation valve With intake manifold flap 2 - Intake manifold flap changeover valve (N239) 3 - Injection nozzle with needle lift sender (G80) 4 - Diesel direct injection system control unit (J248) With altitude sender (F96) 5 - Electromagnetic EGR valve (N18) 6 - Charge pressure control solenoid valve (N75) 7 - Air mass meter (G70) 8 - High heating capacity relay (J360) Only for models with optional equipment 9 - Low heating capacity relay (J359) Only for models with optional equipment 10 - Coolant temperature sender (G62)
K Fig. 2
1 - Glow plug relay (J52) 2 - Diesel direct injection system relay (J322) 3 - Clutch pedal switch (F36) 4 - Brake light switch (F) and brake pedal switch (F47)
Edition 03.98 S00.5111.52.20
------------ 23-3 ------------
Overview of fitting locations 08.00
23
OCTAVIA
Components A to E are not shown in the illustration. direct injection
------------ 23-3.1 ------------
) 0 & & % " ! ! " 2 5' %! '$ 4 # ) 2 3 !1 &! ' 2 (
electrical centre page 23-3.2, Fig. 3 light switch and brake switch combined in a housing in footwell at brake pedal page 23-3.2, Fig. 3 switch in footwell at clutch pedal page 23-3.2, Fig. 3 E electrical centre page 23-3.2, Fig. 3 sender in footwell at accelerator pedal page 23-6
Edition 12.00 S00.5111.54.20
OCTAVIA
Fuel Formation/Fuel Injection 14 - Plug connection 2-pin for needle lift sender (G80) 15 - Plug connection 3-pin for engine speed sender (G28) 16 - Plug connection 10-pin for fuel temperature sender (G81) for quantity adjuster (N146) for modulating piston movement sender (G149) for commencement of injection valve (N108) for fuel shut-off valve (N109) 17 - Commencement of injection valve (N108) 18 - Fuel shut-off valve (N109) 19 - Fuel metering control of injection pump with fuel temperature sender (G81) with quantity adjuster (N146) with modulating piston movement sender (G149) 20 - Intake manifold pressure sender (G71) and intake manifold temperature sender (G72)
23
1 - Mechanical exhaust gas recirculation valve with intake manifold flap 2 - Intake manifold flap changeover valve (N239) 3 - Injection nozzle with needle lift sender (G80) 4 - Heated crankcase ventilation (N79) only models with optional equipment 5 - Diesel direct injection system control unit (J248) with altitude sender (F96) 6 - Electromagnetic exhaust gas recirculation valve (N18) 7 - Charge pressure control solenoid valve (N75) 8 - Air mass meter (G70) 9 - Low heating capacity relay (J359) only models with optional equipment 10 - High heating capacity relay (J360) only models with optional equipment 11 - Coolant temperature sender (G62) 12 - Vacuum unit 13 - Engine speed sender (G28)
K Fig. 3
1 - Glow plug relay (J52)
2 - Diesel direct injection system relay (J322) 3 - Clutch pedal switch (F36) 4 - Brake light switch (F) and brake pedal switch (F47)
Edition 12.00 S00.5111.54.20
------------ 23-3.2 ------------
23 Servicing injection pump
OCTAVIA
Pay attention to safety precautions page 23-1
Pay attention to rules for cleanliness page 23-1
Removing and installing injection pump page 23-8
Dynamic test and setting of start of injection page 23-13
------------

Note:
------------
Fuel hoses at the engine must be secured only with spring-strap clips. It is not permitted to use clamp-type or screw-type clips.
1 - Stretch bolt Always replace 20 Nm + 1/4 turn (90)
2 - Injection pump gear 3 - Hub nut On no account slacken
Edition 05.97 S00.5111.51.20
OCTAVIA
10 Injection tighten to 25 Nm use ring wrench, e.g. 3035, for removing injection lines always remove complete set of lines 11 12 45 Nm
Edition 12.00 S00.5111.54.20
W Y ` X B $ " T R F Q P F G E S ( ' & ( D 5 7 F U (# # C# I 1 ( ' & # B ' ! 3 9 A ( ( ( H V # # # S # ( # U % 1 ( ' & 9 ! # # 8 8 # # #& #% G! 6 5 7 & I I ) # 5 4 (' ' 3 & 1 0 ' 2$ 2@ "
Fuel Formation/Fuel Injection 13
23
for feed line 28 Nm
replace
for cylinder 3 with needle lift sender removing and installing, testing page 23-16 tighten screw for return-flow line of cylinder 3 to 10 Nm
Fuel 20 Nm
1 1 1 1 1
for return-flow line 28 Nm
to control valve/fuel filter
20
21 22 23 2 2
Note:
Fuel hoses at the engine must be secured only with spring strap clips. It is not permitted to use collar-type or screw-type clips. 1 to fuel tank
2 Feed line from fuel tank
do not mix up, blue ring at top
fitting location: arrow points toward fuel tank if filter replaced, remove retaining clamp and take off control valve with fuel lines connected passage to filter opened at temperature below +15 C passage to filter closed at temperature above +31 C
------------
------------
23
Fuel Formation/Injection 1 - Retaining clip 2 - Return line from injection pump 3 - Feed line to injection pump
OCTAVIA
4 - Fuel filter the direction of flow is marked by arrows for removing loosen clamping screw at bracket do not mix up connections replace if damaged fill up with diesel fuel before installing 5 - Gasket replace if damaged 6 - Drain plug to ventilate remove the retaining clip of the preheating valve and remove preheating valve with the fuel lines connected, loosen clamping screw and pull the filter upwards release and drain approx. 0.1 litre fluid
Assembly overview of throttle mechanism

For vehicles 07.98 1 - Allan screw 10 Nm
2 - Accelerator pedal position sender (G79) inspecting page 23-47 setting page 23-7 3 - Pulley
4 - Spring washer 5 - 10 Nm
6 - Thread cage
7 - Pedal bracket
------------ 23-6 ------------

Edition 09.03 S00.5111.55.20
OCTAVIA
K-
Edition 12.00 S00.5111.54.20
E HG F C C B @ D # 0 0 7 8 5 3 0 3 6 6 7 1 22 ) ( ' & % # " 3 4 9 $A!112

23
1 racket 2 pedal testing page 23-47 pedal 3
accelerator pedal
and
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Hand-held multimeter, e.g. V.A.G 1526A Test box V.A.G 1598/22
If the sender has been removed:
Install cable pulley in position shown.
Install sender with preassembled cable pulley.
Connect vehicle system tester V.A.G 1552 page 01-2.
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100.0
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23
010
000
2 C
2 C
00
010
(G79)
Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAV1A
23
Disassembling and assembling air filter
1 - Air mass meter -G70 inspecting page 23-35. 2 - Gasket ring 3 - Air filter top part 4 - 6 Nm 5 - Air guide in air filter top part guide
6 - Filter element 7 - 10 Nm 8 - Air filter bottom part 9 - Air guide 10 - 6 Nm
Edition 01.04 S00.5111.56.20
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OCTAV1A
Removing and installing injection pump

Special tools, aids and testers required Adjusting straightedge MP 1-312 Adjusting device for TDC MP 1-313 Rig pin 3359 Counterholder MP 1-216 Key for the timing belt tensioner (e.g. Matra V159, Hazet 2587, Stahlwille 127-17) Connection fitting e.g. V.A.G 1318/10 Vacuum pump (e.g. V.A.G 1390) Torque Ring spanner for injection lines (e.g. 3035) Puller T40001 with hooks T40001/2 and T40001/3 Feeler gauges If necessary steel straightedge (tear-off tool) Transparent plastic line Removing Remove right headlight Electrical System; Repair Group 94 Remove engine cover. Remove all the fuel lines from the injection pump.
Note:
Use the open ring spanner e.g. 3035 for removing high pressure lines. Cover the openings with a clean cloth. Remove plug from the intake manifold pressure sender and the intake temperature sender. Remove air guide pipe between charge air cooler and intake pipe.
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Edition 01.04 S00.5111.56.20
OCTAVIA
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Remove the top toothed belt guard, the vacuum pump and the cylinder head cover. Remove sound-absorbing pan and air guide pipe between intercooler and turbocharger.
Engine installed KTake off cover at inspection opening. Position the crankshaft to TDC of cylinder 1 -arrow-.
Engine placed down on floor KScrew in setting device for TDC point (MP 1-313, as shown in the illustration. Set setting device to 96 mm -arrow- (the left notch of the vernier -arrow A- is the reference point). Rotate crankshaft until TDC marking -arrow B- on the flywheel is aligned with the edge of the setting device.
Engine attached to engine holder MP 1-202 KPosition flexible steel ruler (marking tool) against the circumference of the flywheel. Measure exactly 100 mm from the TDC marking -arrow A- and make a mark -arrow B- as an aid with marking tool.
Edition 03.98 S00.5111.52.20
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OCTAVIA
K-
Screw in adjusting device for TDC MP 1-313 as shown in illustration. Set adjusting device to 91.4 mm (the lefthand notch of the vernier -arrow A- is the reference point). Rotate crankshaft until the help marking on the flywheel is aligned with the edge of the adjusting device -arrow B-.
For all cases KLock the camshaft with the adjusting straightedge MP 1-312. The adjusting straightedge should be centred as follows: Rotate the locked camshaft until one end of the adjusting straightedge makes contact with the cylinder head. Use a feeler gauge to measure the clearance produced at the other end of the adjusting straightedge. Insert a feeler gauge equal to half the clearance measured, between adjusting straightedge and cylinder head. Now, rotate the camshaft until the adjusting straightedge touches the feeler gauge. Insert a second feeler gauge with the same thickness at the other end between adjusting straightedge and cylinder head.
K-
Slacken the bolts -1- attaching the injection pump sprocket.
Notes:
Use the locking pin 3359 for counterholding the injection pump sprocket page 23-12, Fig. A13-0052. Always moisten the locking pin with oil. Use a mirror to make it easier to insert the pin. If it is not possible to lock the injection pump sprocket with the locking pin, rotate the crankshaft so that the holes for the locking pin are aligned. Then, slacken the bolts of the injection pump sprocket and, only now, position the crankshaft to TDC. On no account, slacken the central nut -2- of the injection pump sprocket otherwise the basic setting of the injection pump will be altered and can no longer be set with workshop tools.
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Edition 03.98 S00.5111.52.20
OCTAVIA
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Unscrew the nut of the tensioning pulley. Take the toothed belt off the toothed belt sprockets of the camshaft and injection pump. Unplug the connector for the electrical connections of the injection pump. Unscrew the securing bolts -1- at the mounting bracket.
K-
Note: On no account, slacken the central nut -2- of the injection pump sprocket otherwise the basic setting of the injection pump will be altered and can no longer be set with workshop tools.
K-
Then, unscrew the securing bolts from the rear support -arrow-. Take off the injection pump.
Installing Insert the injection pump into the mounting bracket and first of all attach the bolt at the rear support with the tapered nut. Insert the front securing bolts and tighten the bolts to 25 Nm. Loosely secure the injection pump sprocket at the hub with new securing bolts (do not rotate injection pump sprocket).
Edition 03.98 S00.5111.52.20
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F F H I G 6 % C D & 4 E 7 ' ' 1 6 # A ' @ # ! 6 1 8 # 8 9 # # ' # ! ! B ! ' 1 6 ' ! 8 7 6 ' 5 $ 4 1 3 3 3 2 )! 4 1! 3 3 3 2 # 4 1 3 3 3 2 ( ) ' # ( 0 ' # % & $ $ ( # " # ! ! !
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The adjusting straightedge must not be used as a counterholder when slackening and tightening the camshaft sprocket. Counterhold camshaft sprocket with special tool MP 1-216.
Note:
Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
23
Note:
K Ensure the retaining claw is correctly positioned. Tighten the securing nut to 20 Nm. Once again, check the TDC marking at the flywheel. Tighten the new bolts for attaching the injection pump sprocket to 20 Nm.
Note: The bolts for attaching the sprocket must only be used once as these are stretch bolts.
Tighten the bolt for attaching the camshaft sprocket to 45 Nm (counterhold with MP 1-216). Remove the locking pin 3359. Remove the adjusting straightedge MP 1-312 from the camshaft. Rotate the crankshaft two revolutions in direction of rotation of engine until the crankshaft is again positioned at TDC of cylinder 1. Check whether the injection pump sprocket can be locked with locking pin 3359.
If it is not possible to lock the injection pump sprocket: Rotate the crankshaft sufficiently until the holes for the locking pin are aligned and lock the injection pump sprocket with locking pin 3359. Slacken the bolts attaching the injection pump sprocket. Rotate crankshaft until the help marking on the flywheel is aligned with the edge of the adjusting device.
If it is possible to lock the injection pump sprocket: -
Tighten the bolts attaching the injection pump sprocket to 20 Nm + turn (90). Remove locking pin 3359.
Edition 03.98 S00.5111.52.20
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OCTAVIA
K-
Connect the injection lines, fuel feed line and electric cables. Fill the injection pump with clean diesel fuel as follows: Screw the connection fitting V.A.G 1318/ 10 into the return flow opening of the injection pump. Connect the vacuum pump (e.g. V.A.G 1390) to the return-flow opening with a transparent fuel line about 1 m long. Operate the vacuum pump until fuel flows out of the return-flow opening. Do not draw fuel into the vacuum pump.
Close the return-flow pipe. Install top toothed belt guard, vacuum pump and cylinder head cover. Install air guide pipe from intercooler with hose to the intake manifold. Install connectors at intake manifold pressure sender and intake manifold temperature sender. Install right headlight Electrical System; Repair Group 94; Exterior Lights/Bulbs/ Switches. Install top engine trim panel. Install sound-absorbing pan and air guide pipe between intercooler and turbocharger. Dynamically test and set commencement of injection page 23-13.
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Edition 03.98 S00.5111.52.20
OCTAVIA
Initiate basic setting 1 2 3 4
Edition 12.00 S00.5111.54.20
6 5 7 5 4 2 0 1 1 1 ( ! & (" ' & " " %! " ! ! %% " " &2 &%3 $ $% # )
23
t commencement
Notes:
and injection
Commencement of injection must always be checked and set, if necessary, after replacing the toothed belt or also after slackening the bolted connections at the injection pump or at the toothed belt sprockets. Dynamic testing of commencement of injection is only possible in function 04 Basic setting of engine as, during this function, the commencement of injection valve is constantly actuated and the injection timing device is thus retarded. t t and
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
Torque wrench 5...50 Nm (e.g. V.A.G 1331) Counterholder MP 1-216 Locking pin 3359
Select function Basic setting, display group 001 page 01-21. Check readout in display block 7 (coolant temperature).
0 9
10
K-
Specification: less than 73 (equals 85 C)
Do not continue with the test until the coolant temperature is reached.
Commencement of injection in display block 2 is dependent on the fuel temperature in display block 9. Specification: Figure - range C
A - Display block 2, commencement of injection B - Display block 9, fuel temperature
C - Specified range for commencement of injection
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Provided the check reveals that the commencement of injection is within the specified range -C-, it is not necessary to carry out any new setting. After replacing the injection pump and the engine control unit, the commencement of injection should be set to the mean value.
Note:
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Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
23
Slacken the third bolt attaching the injection pump sprocket and turn the pump shaft slightly: Turning shaft to the left commencement of injection retarded Turning shaft to the right commencement of injection advanced
Note: On no account should you slacken the nuts -2for the hub otherwise the basic setting of the injection pump will be altered and cannot be set with workshop tools.
Tighten the new bolts for attaching the injection pump sprocket to 20 Nm + 1/4 turn (90) (counterhold with locking pin 3359).
Note: The bolts for attaching the sprocket must only be used once as these are stretch bolts.
Install top toothed belt guard. Install air guide pipe from intercooler with hose to intake manifold. Plug in connectors at intake manifold pressure sender and intake manifold temperature sender. Install top engine trim panel. Install right headlamp Electrical System; Repair Group 94; Exterior Lights/Bulbs/ Switches. Once again check commencement of injection for specified value.
If the commencement of injection is not within the specified range: Correct the setting at the injection pump sprocket.
If the commencement of injection is not within the specified range: Check fuel injection control page 23-28, replace injection pump if necessary.
Injection pump is o.k.: Replace engine electronics control unit page 23-20.
Edition 03.98 S00.5111.52.20
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OCTAVIA
Removing and installing and testing injectors

Note: Faulty injectors cause the following problems:
Loss of power Excessive black smoke in exhaust Intensified blue exhaust when starting from cold High fuel consumption Engine overheats Knocking in one or several cylinders Misfiring Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Injector tester (e.g. V.A.G 1322) Delivery pipe V.A.G 1322/2 Torque wrench 5...50 Nm (e.g. V.A.G 1331) Ring wrench for injection pipes (e.g. 3035) As need be, puller for valve stem seals MP 1-230 and auxiliary tool Removing Use the ring wrench (e.g. 3035) to detach the injection pipes. If necessary, unscrew banjo bolt for returnflow pipe (injector of cyl. 3).
Note: Always remove all of the injection pipes. Do not alter the shape.
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Unscrew securing bolt, take off tensioning clamp and remove injector. Shop-make the following auxiliary tool for injectors which are tight:
Edition 05.97 S00.5111.51.20
OCTAVIA
Fuel Formation/Injection Preparing an auxiliary tool KSaw off an injection line (e.g. spare part line) approx. 5 cm behind the nozzle union nut. Hard solder an M6 bolt to the sawn off line. Thoroughly clean the auxiliary tool, the injection nozzle cannot be used if dirty! Tighten the union nut of the auxiliary tool on the jammed nozzle and insert the extractor MP 1-230 on the welded nut.
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Note: Store the auxiliary tool with dust protection for future use. Installing Note: Always replace the copper seal and O-ring between the cylinder head and injection nozzles. Insert injection nozzles. Pay attention to correct fitting of the bracket in the cylinder head. Insert clamp and tighten fixing screw.
Tightening torques: Injection lines: 25 Nm Banjo bolt for return line (cyl. 3): 10 Nm Screw for clamp: 20 Nm Testing Connect vehicle system tester V.A.G 1552 and activate the function Reading measured value block page 01-28.2. Reading measured value block, display group 013, engine in idle page 01-47. Specified value: -1.50 mg/H...+1.50 mg/H (milligram per stroke) If one or several specified values are outside the tolerance, interchange the injection nozzles (except for the nozzle of cylinder 3).
Reading measured value block 13 0.82 mg/H -0.12 mg/H 0.49 mg/H
K-
Edition 09.03 S00.5111.55.20
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23
Fuel Preparation/Fuel Injection -
OCTAVIA
If the fault moves with the injector, replace the relevant injector. If the fault remains at the cylinder, test the compression. If the compression is o.k., replace the relevant delivery valve together with seal page 23-4, Servicing injection pump.
Notes:
Always use a soft object (plastic, wood) to remove the seal from the pump otherwise the sealing surface may be scratched. If the car has covered more than 15000 km, always replace the set of delivery valves. This engine is equipped with 2-spring injectors. The quantity of fuel is injected in this case in 2 stages. If there is any problem with these injectors, it is only possible to replace them as it is neither possible to set the pressure nor to repair the injector.
K Test injectors with injector tester (e.g. V.A.G 1322) and pressure pipe V.A.G 1322/2.
Important! When testing injectors, ensure that the fuel spray does not strike your hands otherwise the fuel will penetrate into the skin as a result of the high pressure and may cause severe injuries.
l Pressure gauge switched on Slowly press the pump lever down. When fuel ejection starts, read off the ejection pressure. If the ejection pressure differs from the specified pressure, replace the injector. New injectors 19...20 MPa 17 MPa
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Wear limit
Testing for leaks l Pressure gauge switched on Slowly press the pump lever down and maintain the pressure at about 15 MPa for 10 seconds. During this time, no fuel should drip out of the injector opening. If a leak exists, replace injector.
Edition 05.97 S00.5111.51.20
OCTAV1A
23
Wiring and Component Test with Test Box

Note: For testing use e.g. the handheld multimeter -V.A.G 1526 A or B-, also the voltage tester e.g. -V.A.G 1527 B-. For connecting measuring equipment (e.g. voltage tester, handheld multimeter etc.) always use the adapter cable set e.g. -V.A.G 1594 A, B or C-
The contact numbers of the connector of the control unit and the socket numbers of the test box are identical. Attention!
To avoid damaging the electronic components, switch on the relevant measuring range before connecting the measuring cables and comply with the test conditions. Special tools, aids and testers required Test box -V.A.G 1598/22- or -V.A.G 1598/31Test procedure Switch off ignition.
Unscrew windscreen wiper arms and remove cover of plenum chamber Body Work, Repair Group 66. Release the plug locks and unplug the plug connector of the engine control unit.
For the test box -V.A.G 1598/22KConnect test box -V.A.G 1598/22- to connector of wiring loom. Perform test as described in the relevant repair sequences.
Edition 01.04 S00.5111.56.20
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Notes:
Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
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Edition 12.00 S00.5111.54.20
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OCTAV1A
Replacing engine control unit

Special tools, aids and testers required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3CConnect vehicle system tester -V.A.G 1552and select engine electronics control unit page 01-2.
038906018.. 1.9 l R4 EDC G00SG 1002 Coding 00002 WSC 01234
K The control unit identification appears in the display, e.g.: Part no. of control unit part and write in coding. End output (function 06).
Removing Switch off ignition.
Unscrew windscreen wiper arms and remove cover of plenum chamber Body Work, Repair Group 66. KRelease the plug locks and remove the control unit plugs. Use a screwdriver to push the catch of the fixture to the side and pull the engine control unit forward.
Installing The installation occurs in reverse order. Check current coding and code new control unit page 01-23.
Adjust the engine control unit to the immobilizer control unit Electrical System Repair Group 96. On vehicles fitted with CCS; activate CCS page 23-54. Interrogate the fault memory, erase the fault memory, if necessary eliminate any faults which exist page 01-5.
For vehicles 08.03 Generate readiness code page 01-26.
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Edition 01.04 S00.5111.56.20
OCTAVIA
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Edition 12.00 S00.5111.54.20
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Fuel Formation/Fuel Injection 11 K K
23
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tem
Have a second person operate V.A.G 1552.
Warning!
01
and
Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
Fuel Formation/Fuel Injection If the charge pressure measured is too low, the following faults are possible: Hose of charge pressure control dropped off, leaking or blocked. Charge pressure control solenoid valve (N75) blocked. Mechanism (linkage, shaft) of bypass valve stiff or jammed (bypass valve constantly open). Pressure unit leaking. If the charge pressure measured is o.k., repeat measurement of charge pressure with charge pressure control: Plug in connector at charge pressure control solenoid valve (N75). Read measured value block, display group 011, engine idling page 01-58. Accelerate vehicle in 3rd gear at full throttle for about 1500 rpm. At about 3000 rpm check readout in display block 3 and note.
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Models 07.97 Read measured value block 3090 rpm 1866 mbar 1917 mbar 11 62 % K Specification in display block 3: 1800...2050 mbar Models 08.97 04.99 Read measured value block 3090 rpm 1866 mbar 1917 mbar Read measured value block 3090 rpm 1866 mbar 1917 mbar 11 62 % K Specification in display block 3: 1700...2080 mbar Models 05.99 11 62 % K Specification in display block 3: 1850...2250 mbar Continued for all models If the charge pressure measured is too low, the following faults are possible: Electrical fault in charge pressure control solenoid valve.
Charge pressure control solenoid valve (N75) jamming in open position.
If the charge pressure measured is too high, the following faults are possible: Charge pressure control solenoid valve (N75) occasionally jamming in closed position.
Charge pressure increase as a result of tuning.

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

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OCTAVIA
Testing charge pressure control solenoid valve (N75)

Special tools, testers and aids required Hand-held multimeter (e.g. V.A.G 1526 A) Adapter cable set (e.g. V.A.G 1594 A) Test box V.A.G 1598/22 or V.A.G 1598/31 Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Diode test lamp (e.g. V.A.G 1527 B) Test condition l Fuses 29 and 34 o.k. Test procedure Connect vehicle system tester V.A.G 1552 and select engine electronics control unit page 01-2. Select final control diagnosis and activate charge pressure control solenoid valve -N75 page 01-18.
If the valve is not actuated (does not click): KUnplug connector -1- from charge pressure control solenoid valve (N75) and connect diode test lamp between contacts of connector.
Diode test lamp must flash.
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End final control diagnosis. Switch ignition off. Connect multimeter to valve -2- for resistance measurement. Models 07.00 Specification: 25...45 Models 08.00 Specification: 14...20 Continued for all models If the specification is not achieved:
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Diode test lamp flashes.
OCTAVIA
Fuel Formation/Fuel Injection Replace charge pressure control solenoid valve (N75).
23
Diode test lamp does not flash: End final control diagnosis. Switch ignition off.
K Test the following cable connections for short circuit to positive and to negative and also for open circuit (connector -1-). 2-pin connector at wiring loom, contact 1 2 est . socket 2, 28 15
K Test the following cable connections for short circuit to positive and to negative and for open circuit (connector -1-). 2-pin connector at wiring loom, contact 1 2 est . socket 1, 2 62
Edition 12.00 S00.5111.54.20
!
Connect multimeter for voltage measurement to contact 1 of connector -1- and to earth. Switch ignition on. Specification: approx. battery voltage If the specification is not achieved: Switch ignition off. Connect test box to wiring loom to engine control unit page 23-19. . est Rectify any open circuit or short circuit in the wiring. . est Rectify any open circuit or short circuit in the wiring. Continued for all models If no fault is found in the wiring: Replace engine control unit (J248) page 23-20.
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OCTAVIA
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Edition 12.00 S00.5111.54.20
OCTAVIA
Read measured value block 15.4 C
Edition 12.00 S00.5111.54.20
D E B C B 4 $ ) # $ % 6 5 4$ 32 $ $ 2 ) ) 2 0 # 5$ " & ' !17@ (( 2 % 0 & 9 8 A

23
ture sender
t
testers and aids
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Hand-held multimeter (e.g. V.A.G 1526 A) Adapter cable set (e.g. V.A.G 1594 A)
Test box V.A.G 1598/22 or V.A.G 1598/31
Read measured value block, display group 007; engine switched off and cooled down page 01-51. Observe readout in display block 3.
7 16.7 C
K-
Note:
If an open circuit exists in the wiring to the sender, a substitute value of 136.8 C is displayed. End output (function 06) and switch ignition off.
If an implausible temperature, or a substitute temperature of 136.8 C is displayed: Unplug connector -1- from the intake manifold temperature sender -2-.
K-
Connect multimeter for resistance measurement to contacts 1 and 2 of the intake manifold temperature sender -2-.
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23
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Test
Test
Test
Test
50...100
52
25
Edition 12.00 S00.5111.54.20
OCTAVIA
FP F F H I G 0 % ( 2 D 9 C 9 A 9 8 0@ 6" % # % 3% E "2 5% "3 % 3 % % 3 1 # & ( % " ' $ # !!)'!!4B!70!'!! !

If
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OCTAVIA
Edition 12.00 S00.5111.54.20
23
0 2 # " A 3 3 7 " 2 " ) 2 # 3 A 6 0 1 ) ' 1 2 # " " % ! ( f d 9 ( ( @ @ ! @ b f b " r # A 0 ' 2 0 2 " 0 r 0 3 " " # A " 3 1 % x v b t q 0 2 # " A 3 3 7 " 2 " ) 2 # 3 A 6 0 1 ) ' 1 2 # " " % ! ( b d 9 ( ( @ @ ! @ 7 # " 0 # " 3 d f W g 8 8 4& 2 " " " r ) # 2 ' 3 r " 1 y& % Y% X X& u f ` t ! d e $ 7$@ c1 ") "&% 2& # 7 ' 2 # ) " 1& " ' " 1 A " ) ) # A 2 1 %% % % d ! ( i & "& "8 #% & 2@ 0 3 0 2 # ) " A 3 " 3 $ ) (4 !4 ! 7 # " 0 # 3 d f 41 7$ "1 2$ "& " r # ' ) " ' ) 1) " A ) 0 ) 2 1 # " A 3 3 1 % % q $ 8 4% 7 "@ 0& "& "& ' ) " A ) ) 2 0 # 1 1 y1 Y& `% ( ( t 7 "1@ #$% 0$ 2& 3 # A 6 0 ) # " 0 " ) % 9%8 f8 d 9 ( ( s q u ( & $ "1 '1 #1 7 2 # 3 A 6 0 ) ' 2 # " " # A 2 % % (1 b d 9 ( i ( q & $ 8% 41 "q r% #4 A r 0 0 0 ' 2 0 " 0 r 0 " a1 a1 `% @ ` g A$& 't 2%& r8@ 7 # A& 6% ) 2 " ' 3 # " 1& ' # " ) # " (& d 9 ( ( $ & U D P C D E Q D S V y X u f ` W1 87 7 "&& "1 "@ r& )1 #& 2 ' 3 r " 1& " " 1% 2 # 1 1 % % Y1 X1 ! d h Wde W# 8$ # 8& " 2@8 w 17 2# ") )1 a a" Y&p X#1 `td f$# x u%' `43 e$ Y" X b b x u1 `' dr W4" 87 82 rd "9 " "( #( ) $ "$ A # 3 a Y X% X v& u ` X t d ( q W p 8 8 8 7 7 r& " " " ' " 0 # 1 a$ Y4 X1 X s$ bS ` t q ( ! ( W 2 1 a a iI h X f f f f Y X ` ` W W 8 ct 7 " # 3 " " " ) " ) 6 ) " 3 1 a a % Y d ! X b ` $ ! & U8 T1 D% D% S1 Se C G E D P P Q Vq B F8 8 "8 08 " # 0 " # " # 2 3 0 # ) 0 " 0 % 9 ! ( ( 48 7% 28 Ae 2 " # # 3 A 7 " # ) " 0 ) " " ' ) " 1 A ) ) 0 # 1 2 %% ( ( 8e 7 "% #% 0% "g 0 ' 2 0 2 " 3 0 2 ) 6 ) " 0 3 1 " 3 %8% % 9&$ !1 && & 4&&5 "$$ "%& "1 )g$ 0& "% #$ 28 3F " 0 ) " " ' ) # " %% % (1& (% !4 (1 ( ( &$@ $%& ! &% $ &8 $ 1 H %& $& I H % $ %& R % % %
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1013
10
Testing sender
testers and aids
and altitude sender
Edition 12.00 S00.5111.54.20
OCTAVIA
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est est . . est est
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OCTAVIA
Edition 12.00 S00.5111.54.20
K-
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23
OCTAVIA
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Edition 12.00 S00.5111.54.20
OCTAVIA
Edition 12.00 S00.5111.54.20
c d a b a 4 8 4 3 6 ` Q 2 3 2 P 1 " 3 ) " ) X 4 ) ( ( 4 6 8 I Y &F Q 3 F6 F) 1 " 3 ) " ) X 4 0 1 F 0 ) ( W 3 " D 9 8 & B& )" 4 6) " 3 2 " " 1 ) C ' !) ( 5F P 4 8 & 3 U E 8 Q& BB0 1@0 4B5 66 2 ) F ) 4 0F ) ) (0 Q 2 ) ) 45T& ) )V 105!B 470 45!B& & 2 0" " B$ C5!! P 5" #& 3# 207 "!00& "$ 3@ 0I 2 " " 1 0 ' ( & 3#5!& 2F "H0 "S 10 ) F 00 G 0 B 2 2 3 3 " 2 0 (!5H 3!H 14 9 )C F 04 0" 3 " () EH!H D "& 4 ) ( C 9 8& &000 1 ) R5 ) 4" 6$ 00 "05@ 3BB 2 "@ "! "& ' !4 ( " $5& #B #7 # A HB0 50&!A! B07 5"5& ! 0B& @B 0& 50 6 7 0!%! %& H
23 control
1 2 3 control connection at 4 control unit 1 acuum element 2 3 4 valve return valve white connection points toward charge pressure control solenoid valve -N75 acuum unit 6 o air control 8 unit for charge pressure control valve part of turbocharger, cannot be replaced separately 9 10 11 valve recirculation acuum 12 13 return valve
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OCTAVIA
Testing start of injection control

Testing injection timing control range
Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Procedure Final control diagnosis Start of injection valve -N108 Initiate final control diagnosis and actuate the start of injection valve page 01-18.
K Readout in display: Actuation of the valve is indicated by a clearly audible change in the combustion noise (diesel combustion noise). Initiate the basic setting page 01-21.
Basic setting 42 46 0 20
90
201
64
153
0 127
83
K Readout in display, e.g.: Set start of injection, if necessary page 23-13.
K-
Remove the fuse 34 -arrow-.
Basic setting 42 255 0 20
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90 201 64 153 0 127 83 K
Observe the readout in display zone 2. The readout should increase to 255
Note:
As a result of the interruption to the voltage, the start of injection valve is closed. The pump internal chamber pressure can no longer be lowered and acts to its full extent on the piston of the injection control. The injection control is moved toward the advanced stop.
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Edition 05.97 S00.5111.51.20
$ 1 t $ # 0 3 2 3 # # # " $ 0 " % $ 5 & 3 # # # % % 2 3 % ( 0 # 0 2 3 u ' # # 2 # " 0 " # " 0 ( $ " 0 a e U ` T U V y f % 50 &( u y % % v w 0 4 4 q p 3 i &" ' u0 30 x t q p i ' u 3 ( $ 4 q p p i 5 u 3 p s( t %( g (! #h # $ " 4( qs p p( i r 3 s0 e d U U( c0( ` ` c a T X U f Wh S D D 7 H Q P I C( B A 6 (0 " ( " 0 5 & 4 3 2 #0! # 7 $ V 0 ( h 1 " $ 0c 0 %(c (8 U #G $( (0 Y " 'E & x0) ( F (9 ( !Y 0 @ W (R ( 0 (b
If the If the l If the If the est condition t t
OCTAVIA
Edition 12.00 S00.5111.54.20
commencement o injection
testers and aids
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the
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v v x y w u ! c t s d C B A T & X ` & W h H H ` & i g i e d b " " # T & `$ U X P H & U W & & U R H V V Y Ie ) & ' H F 3r 1 0 2 ( f 59 4 2 % 6 D 2 9 q "9 C G S 9 S V @ @ AS A 9 8 Q p $ 9 & ' 3 1 0 2 ( f 5 4 2 % G I E S e V G d bQ c$G a # # T & ` U XB P H & U W & & U R H V V Y ) Ie & ' H F 3 1 06 7 ( 7) 5) 4 29 % 62 D " C @ S G @ A A 9$ 8 V $ 9 & ' 3 1 0 7 ( 7 5 4 2 % 6 9 $ ) E G # "I ! B Q 9 ) G
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23
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Test
Test
connector at
connector at
10
10
Test
Test
14
Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
23
Edition 12.00 S00.5111.54.20
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2 a a ) ! ! ) 1 ) 1 ! ! ) 1 ) ! 1 q R " e a ! 1 ) ! ! ) 1 Y ! ) 1 a a a S ! ) ! ) ! ! ) 1 b 1 w ( I ) v Q Y " " e u W ) ! T T ( ) S ! ) ! b 1 ! ! ) ! 1 ) ! " c p " ( ( ( ' ( 22 a ( I ) h ! Q e T " Y " " u ( S ( ) b ! ! f ! 1 ) 1 ! ( Y )2 ( 1 Ia ! ) h T i s "( " T b Q &0 & p Sa !( ) ) S ) ! 1 ) 1 ! b ! q " "( " " p p ( W ( h Y ) ba 2 I( )( 1 " " Tt i g " H H 22 2 ) ) f Q Q T $ P &a V# $ % dq &( P R R % d & U( H 2 b 1 Q& $ P(( PW e d & P 'c T " H(Y ` 2 2 u b& tx 2 ! Qq $(d P(u P2u c( RQ & y '# # " " H )ah Q Q Y() XT P V Vi V V1 $" P" &g & H H S (2 2 1U I 1 Q Q2 $( T2 a P & 2 ( R2 F E 5 5W D7 Da A A B 4 8 6 5 @ G 7r 3 2 ! ) ! 1 )2( U9 2 ! 2 9 ( 0 2 $a & % " 2( ' #C (W (
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23
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Testing
Test procedure
testers and aids
temperature sender
1.
Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
23
K Test the following cable connections for short circuit to positive and to negative and also for open circuit (connector -1-). 10-pin connector at 4 7 est . socket 76 53
K Test the following cable connections for short circuit to positive and to negative and for open circuit (connector -1-). 10-pin connector at 4 7 est . socket 103 111
Edition 12.00 S00.5111.54.20
0 1 ) ) ( # $ & $ ! % % '" ' # $ & $ ! % % "

Specification: Specification in field A applies to temperature 0...50 C, in field B to a temperature of 50...100 C. Example: A temperature of 30 C equals a specification of 1500...2000 A temperature of 80 C equals a specification of 275...375 If the specification is not achieved: Replace injection pump page 23-8. If the specification is achieved: Connect test box to wiring loom to engine control unit page 23-19. . est Rectify any open circuit or short circuit in the wiring. . est Rectify any open circuit or short circuit in the wiring.
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D F GH G E E B A &) ) & 3& & 4 3 9& 87 74 6 2 @7 5 ' )! & # ( % $ "11 !""0(! """C!
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Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
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Edition 12.00 S00.5111.54.20
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OCTAVIA
Testing exhaust gas recirculation system

Testing exhaust gas recirculation
Operation of the exhaust gas recirculation system is tested by measuring the inducted air mass. If exhaust gas is recirculated, the fresh air portion which is detected by the air mass meter is less. The greater the quantity of exhaust gas recirculated, the smaller the signal supplied by the air mass meter. Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Procedure for models 07.97 Read measured value block 900 rpm 6.5 mg/H 1 87.3 C
Read measured value block, display group 001, engine idling page 01-36.
1.480 V
Check readout in display block 4 (coolant temperature). Specification: at least 85 C
Do not continue with the test until the coolant temperature is reached. Press the key C.
Press the key 0 twice and key 3 for Display group number 003 and confirm the entry with the key Q.
Read measured value block 900 rpm 272 mg/H
3 268 mg/H
54 %
Briefly blip the throttle and then allow the engine to continue idling.
Read measured value block 900 rpm 272 mg/H
3 268 mg/H
54 %
K-
Check the readout in display block 2 (specified air mass). Specification: 230...370 mg/H
If the air mass is higher than specified, the cause may be the following: Coolant temperature too low
Intake manifold temperature very high Injected quantity too high
------------ 23-32 ------------
Edition 03.98 S00.5111.52.20
OCTAVIA
23
Fault in fault memory Read measured value block 900 rpm 272 mg/H 3 268 mg/H 54 % KCheck the readout in display block 3 (actual air mass). Specification: should agree with specified air mass in display block 2 (tolerance 20 mg/H) If the actual air mass is more than 20 mg/H lower than the specified air mass, the following faults are possible: Unmetered air in intake area Excessive exhaust gas recirculation If the actual air mass is more than 20 mg/H higher than the specified air mass, the following faults are possible: Engine has been idling for 3 minutes
Final control diagnosis EGR valve -N18
Edition 03.98 S00.5111.52.20

Insufficient or no exhaust gas recirculation If the actual air mass is a constant 425 mg/H, the following faults are possible: Open circuit in wiring to air mass meter Implausible air mass detected If the specifications are not achieved: Start final control diagnosis and operate the EGR valve page 01-18. The valve should click. If the valve does not click: Test EGR valve (N18) page 23-34. If the valve clicks: Check the vacuum hoses page 23-37. If the vacuum hoses are o.k.: Test mechanical exhaust gas recirculation valve: 1.9-ltr./66 kW Engine, Mechanical Components; Repair Group 26; Exhaust gas recirculation system
------------ 23-33 ------------
% 5 G G S ! 1 9 0 ! 9 " ' ! ' % # " ! # r s@ B t q 8 6 C % ! @ 0 # # " " ! ' 9 1 f$ G G S @ " 0 ! @ 1 Q ` b S 6! C))6 01 @E 0# !( 1 ! ' ' 1 % 1 H# p i U b b ! 1 0@ !B "# C 9 '& ! '$ % # " ! # ! 1 ! &(9 ' && # $' (g )' v v !u 9w 0x 1 ' 1 0 ! # @ ' ' a # 3y v e 4 4 B g 0 ! ' @ A 1 1 # 0 ! @ a( D E 3 W C % d$ 4 5 G 4 B 06 ! ' @ A 1 1 # 0 ! G&6 D(8 E)$ 3 W Q ` U R eh 4 0$ !6 ' @ A 1 1 # 0 ! D E& 3 W C$ %8 R d()((T)) 4 b 4 0 ! ' @ A 1 1 # 0 ! Gc D E 3 W $ ! 96 Q ` U Y(2($ $$(2 %((h 1 ! 0 1 0 Y % 1 ' 0 0 1 Ca "! #& 1 ! 0 # ' ! @ A 1 # " 0 $R 5' 3 G D E 3 Q ` U 1a !@ a Y ! 0 9(' 1 ' 1 1 0 # e Q ` 3$' U D 3 4 B C C %# 1@ !& " '' # 0 ' ! @ A 1 # " 0 $ S D E 3 3 C(8 " 1 @ " 0 % ! @ A 1 & ! G8 48 4 D 3 C)($(( %0 11 a)2 ! # 1 ' # # A 1 0 1 " 1 $' $' W(6 D Xf 5 4 U % ! @ % 1 1 % 1 Sc8 B8 48 3 C)($(( # # A T& # ' 9 1 1 ' R! R' $ S! Q' P)(2 I(6 B9 H 0 ! ' A # G$ D( E G 4 F @ "% 0@ C %# ! @ A! # 0 " ' ! & " 9 ! # 1 ! 3 D E 3 3 ) 6@ # !! #! $8 "$8 !8 # 9 # 1 0 ! " &8 ' " 30 (5 63 C))($(( 09 (8(2 ")($(6 ! #1 9 &' " 0 @ ' 0 0 & 3 26 1(3 0' #3 ' #4 A 9 " @ # ! # 1 0 9 ! & 9 " ' 38@ 4A B' 3 !'64 %'()(( " #S ! )V(((& ## $c$( %6)()$ 1)$8 ()& #8 !8 '2 #$ 1 0 1 " ' $$8)(($ d 8)() )($$ 7)2 5 4 '64 # 12&)(& #3 0# #' 1$))$($ "&& 1)$$ 0(88 '9 !))& "$ & '(% !6 % 'C " # ! # $ $ $& 3! (1 (A 91 &(()(($& )2$(( &$ & $(F) & &(1 ( W $ 2! D # (($A ($cg '($ @ $((( $G# )& & $% )$($)(((' C
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23
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If a constant value of 550 mg/H is shown in display block 3, test the air mass meter page 23-35.
Note:
Edition 12.00 S00.5111.54.20
OCTAVIA
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Edition 12.00 S00.5111.54.20
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@ 7 g a P 6 P P b D A 7 6 6 Q D P Q 6 ` D D X 5 e B 7 A 7 6 a Q 6 Q F P Q 6 ` h c g c B 7 7 A @ 6G a Q G A 7 6 6 Q P D Q 6 ` D 5 e B A f 6 Q ` 6 A 7 6 6 Q D P Q 6 ` D eC B 7 P Q 6 ` c A A 6 Q 7 @ b AG A 8XC 6CGI QCC SIGGW UA TCEEGGCCI Vb Y a 4 P DD D5 XD 6 9XIXIC VDC CD S A` ADC 6Q QQ EREI Ad 66 QT QD Db Q P GU GD CD @ A HCGCCCI 6GW 5I FC8 5C 6EI 6 D B 1E & ! 2 7GCCCCEI 3 6 4 9XIW 1 0 )EA ) # ! & & ' 2AE " C% R EI G%EW 8V $C EI 5 8(" ' ) 5 )$
OCTAVIA
Testing electromagnetic gas recirculation
testers and aids
Hand-held multimeter (e.g. V.A.G 1526 A) Adapter cable set (e.g. V.A.G 1594 A)
Test box V.A.G 1598/22 or V.A.G 1598/31 Test condition l T -
29 and 34
onnect tester and select engine electronics control unit page 01-2.
control diagnosis and Select exhaust gas recirculation solenoid page 01-18. is not actuated (does not
the
K-
connector -1- to the exhaust gas recirculation solenoid
onnect multimeter resistance measurement to the -2-. 14...20 is not
the
exhaust gas recirculation solenoid is
the
onnect multimeter measurement to contact 1 o connector -1- and to earth. ignition on.
the
is not
test box to the loom to the engine control unit page 23-19.
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Edition 12.00 S00.5111.54.20
OCTAVIA
Fuel Formation/Fuel Injection est .
K Test the following cable connections for short circuit to positive and to negative and also for open circuit (connector -1-). 2-pin connector at 1 2 est . socket 2, 28 29
K Test the following cable connections for short circuit to positive and to negative and for open circuit (connector -1-). 2-pin connector at 1 2 est . socket 1, 2 61
Edition 12.00 S00.5111.54.20
& 0 ( 1 ) ' ' ! " $ " % % ! " $ " # # # #

23
Rectify any open circuit or short circuit in the wiring. . est Rectify any open circuit or short circuit in the wiring. Continued for all models If no fault is found in the wiring: Replace engine control unit (J248) page 23-20.
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OCTAVIA
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Edition 12.00 S00.5111.54.20
OCTAVIA
Read measured value block mg/H 1030 mbar 1011 mbar
Read measured value block 830 mg/H 1030 mbar 1850 mbar
Edition 12.00 S00.5111.54.20
(3 # $ )2 0 04 (& '1 & # # & $ ! ) & %" "

23
air mass meter
The signal from the air mass meter is required by the control unit for calculating the permissible injected quantity and for controlling the exhaust gas recirculation. The smaller the signal supplied by the air mass meter, the less fuel may be injected. t testers and aids
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Hand-held multimeter (e.g. V.A.G 1526 A) Adapter cable set (e.g. V.A.G 1594 A)
Test box V.A.G 1598/22 or V.A.G 1598/31 est condition
l Fuses 29 and 34 o.k.
Read measured value block, display group 010, engine idling page 01-55.
Warning!
Have a second person operate V.A.G 1552. Observe readout in display block 1. Specification: 230...370 mg/H
10
0.0 %
K-
If the specification is not achieved: -
Test exhaust gas recirculation page 23-32.
If the specification is achieved: -
Accelerate vehicle in 3rd gear at full throttle from about 1500 rpm.
At about 3000 rpm, check readout in display block 4 and note.
10 100 %
Specification in display block 4: 100 % (accelerator pedal position)
------------
------------
23
Fuel Formation/ Fuel Injection
10 100 %
10 100 %
10 100 %
10 100 %
------------ 23-36 ------------

If the specification is not achieved: Models 07.97 K Specification in display block 3: 1800...2050 mbar (charge pressure) K Specification in display block 1: >750 mg/H (inducted air mass) Models 08.97 K Specification in display block 3: 1700...2080 mbar (charge pressure) K Specification in display block 1: >800 mg/H (inducted air mass) Continued for all models If the specification is not achieved: Test charge pressure page 23-22. Replace the air mass meter (G70). Switch off the ignition.
OCTAVIA
Repeat the test and accelerate the vehicle at full throttle.
If a constant readout appears in display block 1 (fixed substitute value): Models 07.97 = 425 mg/H Models 08.97 = 550 mg/H
Edition 02.99 S00.5111.53.20
I 5 ( 1 4 3 3 4 1 A ( 5 3 ) 4 ( 8 P P v D v w T q v v E i g ` a d a h p d ` ` a X a " 3 6 7 6 4 4 8 ( A 8 5 8 2 5 ( S 4 77 ( 8 5 ) 49 4 A ( 4 I 5 A ( ( 4 3 5 7( 8 3 2 ( 7 3 4 62 P t ( 1 4 ( 4 5 2 8 ) w q Q @3 I 5u 47 49 4 2 ( 5 4 4 s 5 6u P5 P t 5G9 56 8 S 4 ( 3 5 8 ( 4 8 A P 779 G96699R9 4 ) ) 8 s 7 r v v x w G 4 ) ) 8 s 7 5 r v) xT w P 58 2w 8` 43 57 8 S5 u4 4 ) ) 8 s 74 7 r 64 6 v t q 06 58 2` 8R 45 S5 4 ) ) 8 s 5 7 5U 85 u( 7R r 66P 63 P 06( t5 q i g ` a d a h ` `4 1 d( Xb aGb a) "b d ` ` a " ` X a b( eb fV YS YV Y5 4 ( TA (GA 4AY 5c6 I# 33 43 @ 86Y (6 4c A6R 3p 2 ( 3 4 4 5 4 ( 5 6b 6 P3 P Rb Q T5 @67Y @R 5G4 @ 1( 83 5690bW A1 57 26096 89b 47 S 5 5 72 1 5 ( ( 4 3 7 4 7 H G7 I 3 (G99 46 ( 4 ( 2 P ' G1 @976969 @6966 53 50A 86pR A3 A966997 8c 8606 46 5 ( ( 769R6 4 30 2 ) ( 3 7966 D5 667 C0P9 E306 F5 Bc0W $ " &9 99Y 99 % ! 9Y 6 90U Y0R 6#6 9y 7 96 06# 6 66
est . est
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OCTAVIA
Edition 12.00 S00.5111.54.20
K-
. socket
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23
8 $ # " " # 0 $ " " ' % 9 9 Y Y W I U H I R V P XI u R H H I D x w # v H F & y t s H # # ' 0 ' $ ' ! $ B # &! ' $ h h # # 0 # 8 $ 0 # " $ & ' " ! & " # %& 9 b $ ! ' # # q p i Y ) 8 $c # # # ! $ # # a $ % 9 9 @ b $6( $ ' B # " $ ' # ' 0 h&( 9 6 #& " & ' a$ &c ` e(((% f%%%((A( d # ' a & ` e f 9 d $' !$ '6& #" $# '% B c$ # ' a &A & ` %# % b %" Y $' !p 'Ar #I $6 '$ BB c# # ' a & $ & ` %9 %$ b$ 9 %D Y WG U H I R I V H R H H I H F I H# $ R FPQ ICPG I X D P S& T G$ G G$ # $ 6# #0 $Q& 8E "" #0 ) '%6 # 0( "P ! " # # $ # $ %P 9P(%G 9 AP 0 )%%X )% $%" ) '" $P% 0 $" !%A '" #& B $ $ &! $ # " & # & @ 6% 8( A((( #(((% & # % ! " 7 9 6 )(&%(% )%%% $" $P%G '&C 0((AQ 0(%%% '%% '& #% $A &0 # "( ! " &(%% 3$ %%%(E 29 4"( 56%&(((% 1Q%% ( ( Gg G % (A
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23
est
52
50
Edition 12.00 S00.5111.54.20
OCTAVIA
v " % ! ! u e Y 3 6 " ! 7 p W q H Q x y w y 6 v " ! ! ( " # 7 7 f u t 2 d e e d Y h A W H G q T F G Q G I r X Q F F D " " G ! % H !2 !d %Y ( % " % " @ ! $" % ! p p !Y ! ( ! 6 " ( ! " $ % $ ! # 7 b ! ! " % iA h4 d Y 8 '$& 6&# " !" !# ! " ! ! a " #) 7% 7 b 4H !% ! %B&#&9 a $$& ` f#( gs&99 d# e 4F !$S c #P %VVI a $&V " ` f!E gF "7$&& "4 %% !F "! %" @#c ce ! % a $ ` #F #! b d Y Y "79& # %% !9@ "$$& %$#& @$& cY ! % a $#&( " ` #U #4 b h W T F G Q G U FF #4 Q" D G G H Q F F G H F D I$ R S EE9 ! AG " ! " 6 !#I ' %&I # !$ (&$ ! ! " ! " #P # # 7" 7 8 A$# '$#P ' "" ' 4" % " ( "I $ %9 !I @# " " $( !$ 5 4X 6 ! ! 7 4G 'I##E '#9C "P$E "! %&&I&#E (( ($&& %VE % ! " $! ! $# 1" ##I 09" 2AI&### 3E7 )" E# # $ #&B#&&&&& &###&VE &## P X#9# &##&4# C ##&$
est . est
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OCTAVIA
Edition 12.00 S00.5111.54.20
KT
K-
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Edition 12.00 S00.5111.54.20
1 B 1 4 @ ! # ! 0 b P 9 T 4 T S 6 # 4 0 # 0 3 1 ! 0 ( 0 ( ) ) ! 1 @ 0 @ B D C '! 9 40 ( ( 6 ! # 4 0 # 0 3 1 ! 8 6 ( ! 8 0 ( ) 7 2 4 ! # # ! a Q % B '! 5' 0% 18 @D 22 !8 #"' 4' !' T #' # 6 ! ! 0 ` ) "5 25 ! F R S 1 B I 4 # Y B X W V 9" A2 68 !E5 12" @5 ! T 0 ( 0 1 8 0 1 ! 0 ) P 9 T' 0 1 0 G5" 1Q !! 8 0"8 6' 1 1 T 8 # 58 P@ S 2 $ $ D $ B X W V 9 8 6"A !"" 18 @8 !5 TG 0"2 (E ' 0 1 8 0 1 ! 0 )5 P 9 T' 0 1 0 G8 1% ! 8 0D 8G 6E 1' 1' T # 5H P# S 2G 9' T 4 T S 1 B I 122 45 A @' !2 # ! 0 P F ! F !U 1 @ 0 @ B' D5 C' '! 9 40 (! (EG 65" !8& #G' 4G 022' #2G 022 3E 1 !" 8Q 6 ( ! 8A 0 ( 52" )22 7 2R 1 0 ( 0 ( ! 62"" #G' 42' 08 #G 0' 3" !A 5"" )5 ) "' # % $ $ $ 52" G2 5U ! H 5 52" 5" 5 & ' 2' 8' 8
recirculation
13 12 11 10 9 3 2 1 3 1 2 valve unit for charge pressure control valve part of turbocharger, cannot be replaced separately models 08.97 return valve white connection points toward charge pressure control solenoid valve -N75 models 08.97 valve o air o o air acuum acuum acuum acuum unit acuum return valve return valve control element element recirculation recirculation
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OCTAVIA
Edition 12.00 S00.5111.54.20
valve
valve
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23
j l m k k P 1 & ( A 6 1 ( & y ( 9 4 & ( ( 8 6 & 9 h 0 0 0 % D T G S A A & A B 1 & 9 & 2 1 ( ( ' & & 4 B & 6 6 ( 8 4 4 0 e i e d P 10 & ( A 6 1 ( & y ( 9 43 & ( ( 8 6 & 9 h 0 0 0 %) D T x S0 A A &3 A B3 10 & 9 & 2 1 ( ( ' & & 40 B & 6 6 ( 8 4 4 0 e g g e d f P0 S 6 B ( 6 ( & 6 2 6 8 & 4 &0 20 1S C 0 w U G5 H A0 &50 (0 (0 (0 & 6 6 ( 8 0 20 65 &S ( ( y & 9 4) 0) 0f 0 %3 )) % T 50 p Y e X Y ` f Y h q & 1 @ ( & 2 1 ( ' ( 6 1 & B 9 9 G x D w H Q ) 0 bS e Y X X p f e Y b h f Y 0 d 55 c a P0 P0 ( y 4 ( & 9 V V u t UP s Gh w U u t H s H w U $ T Pd P 2 & & & 1 9 & C 1 8 V u t0 t s x w U t IP T D E r P4 P0 P & 6 1 A A 2) &0 & & B 4 V u tP t s vP H U I D % D E e e f p i Y Y h h X b ` Y q W a P A 6 B ( 6 ( & 8 6 ( 9 @ 9 & 6 8 & 4 & 8 0 0 D 5 S A & & 1 1 6 & 2 B ( & C C 1 2 6 & & 4 2 1 Vc 0 0 Dc %d U0 % % D 5 T ) R S0 (a &) 1P 'P 9d & & 6 9 9 & 8 ( ( 9 8 1 & & @ ( 09 0 0 H H G F ) Q % 5 H H G A0 1PE &P @)5 &5) 65 (I 94 @7 9d &5 67 80 & 40 & 8 & & 9 2 B ( 00 0 D D % % )5) % A0 &I C0 C0 BE &5 90 9S 6c ( 94 @) 90 & 6 & 8 ( & 2 1 ( & ' 0) DF % $ 550 )0 % 55 #a "40 ) 4 c P 5 ) 5 5 g !4 5 4 ) 00 0 70 4 4 3 5)
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Test
Test
Testing control unit rameters
Test conditions
Testing rect injection
testers and aids
diesel
Edition 12.00 S00.5111.54.20
OCTAVIA
" ! % ' % $ " " ! %' ' $ ! 9 " ! " % ! d b "! !% "' !$ %% ' " ! 9 % ' 0 % 5 $ " % ) ' B' 9! 5% !% "% " $ ' 51 % % 1 ! % ' a5 " $ B" % ! "' 5% 1 536 % ! 1 % % % ! % $ % e 6 6 " % % 5 " % " ) 6 %6 "b % ! ! ! 5 " % " % ' % ' % " % e` e% X! ) D % ' $ ! 9 " ! " % ! c" ` e b 8 B" %$ "% "% "X ! % " " % % 5 ! ! 6 ' ) %0 %0 ' 2 " ! ! " ' 6 " a C D% '(5 % % "5 $" '% B %% 1' %! !! %0 0 9 5 ' 1 b X B5# %0! !$ " 5! 1! 5 % ! " % % 09 % " ' $ ! 6 6 !&& " ! y0 y# w&34 x iD g s q3 T0C3 h T u t r f "( ! ' % 9 5 e d X 6 c b @ Y #F BC#13&4 "(' '# ! % " $ $ 9 1 % ' a0000 X `# W "03330 % ' " 2 X3 5& (3 V F P P T& T S R U I" t % 03 G H F ' 5 ! % ! ' 5 " 0 603 ) E 8 C! D! ! % B&4 ! !% 9 '5 '5 5 ' " ! #% @5& @% 6% A @3" @ " 7 ! % ! " ' % $ % %5 ' 25 " ! 5 % (1 630 CQ %5 '0 " % ' 2 1 ! " ' % $ ) !# " ! " ! 300&033930p#3533##v0&#30##p3&&(03&433 0 (
It is not easy to hear the clicking of the relay and this is therefore best detected by feeling. Note: l l l jection . actuation d direct i
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OCTAVIA
Edition 12.00 S00.5111.54.20
23
% i ( ! # )v x 0 f ( y w % ( u 0 % 1 0 % t s ! 1 ) $ ) 1 ' % ( # ( % 1 %! " i ! g " " % f ' q # ( i h " % hp r # ' 0' % 1 0 W i X ) $ 0' q ($" ( # " % ggp g ( ( i $ %" " 1 h " % f ) p 0 f ( D B 3 e b R S c d 0 # a X $ 0 ) 1 0 Y Y ` Y Y ) 0 1 1 % (' ( ! W D 2 B 3 3 B 9 5 Q V C 7 H B 3 3 4 3 3 2 6 D" E @ 9 5 Q I G U1 F' U S R P6 Cg A T 1 % $ 0 % 1 "H $ ) 8 0 ( # " ( % & $5 " ' 7 ' ! 8 7 # ! " " '
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It is not easy to hear the clicking of the relay and this is therefore best detected by feeling.
Note:
Electrical
contact
Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
Edition 12.00 S00.5111.54.20
q v s w u t r B b a G B R B R P P G Bb G R H B H R @ T B p b d e b i @ c 8 C RII R C R 8 H V R R B ` U f I G V R b a B B R P P Gb R HH B HB R V T R g H R R fI9 U9 e RXA H db a YIc` 7I9 a 8c b D G9I R Ri b a 9 `9 V GI I B R B P P I Gh P R H BU HX R V Y T C R UIA $ % 3I 2c )I ' 0W & S` # ! HA R Q H F I D 9 GA H EH E P E E C B9 @ 8R 8 7 $B " 6 59 # 0 1I ( $B % " A A 1 ) ' 5T &" 5R9 3 2Y 0 # ! 4" IIc XÌI 4 W I(9
23
Test the following cable connections for short and also for circuit to positive and to open Electrical contact . open circuit or short circuit in the binder ting low . 1 ignition diesel direct position holder Note: It is not easy to hear the clicking of the relay and this is therefore best detected by feeling. If the specification is not achieved: test box to the wiring to the engine control unit; engine control unit is not connected page Use an adapter cable to connect diesel direct holder position unit is connected: engine control unit page If the does not operate: witch ignition off holder diesel direct base position
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S u T Q W U U V U U Sw # A 3 $ 4 )S c " " # 0 ) # $ # # " % d Y Y 2 S S W T Q W W W Y! S Q W X S w w u W W x S ! R 4 B f g 4 5 # A 9 7Q F 6 F C B @ 3 b # 4 c # g Q q y H i W w i s Q U S ) & 2 p !2 W'' & r( q% i h i $ 4 2 $ 4 " # g e $!Q ) 4 # c c b 0 ` 2 4 # ) $ & 2 # % fv E (S d T Qq Wx 1 u U Ux 2 V U U #Q 2 t8( # 8 S X " 8 R P I1 H 4 # "1 2! # 2 % GD% F 3 @ ' 8a 41 5S 2 # 0 ) # $ # # " & A` 9Q 7 @ 6 E Cq B @Y! 3 1 Dw ) &% (u % ! ' ( & S % ' %& S S !% !% (Y ! x w ! Y YQ v% !! t
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Electrical
Electrical
contact
contact
Edition 12.00 S00.5111.54.20
OCTAVIA
B $ $ C A ' c c d c B ' ' & 7 7 ' ` 4 B ' ' & 7 7 ' ` 4 C B ' ' & 7 7 ' ` 4 B' '$ B 1 5" 'e & 7 7 ' ` 4# F P1 S' E E1 R v u X T$ Y ' `" C 8 7 ' $ B 4Y "b @ # AY ' ! B9!@ 'A A # 4 p V 9!' # $ $ # # # ' ' $ $ " # 4 0' 04 q8 B ' 7 $ 859 0$ 1$ i" @ B CD Y "T B9 $B $ h F f $ 1 8 '"X # ' #c $$ #T$ '$ B$ ' ' "$ !5 ' 7 # ' B $ $ # e 5$ "" B1 $y $1 C A '# B cW c A d c C B P '6#6$ !"t $ ' 7 # r!""" ` 9B 1 7 7g '# `($ ' "1 #33a B' '4 @ ' &' "q Y 4# V W F' P S!` E E Q P F E R T' T '" $ & C T ' $ ' #$ B $ # "8 E !c @ 5G F "4 A& 'D # s B$ $ $ 'P # !' $9 7 & ' 1# 83& 5G$ 'I# &' G '$ $A '' 9$ ' " X UU7 b 4" ($ 1 1 ) wx $!' &7 & $" # & #2"9' U!$6H!I"!6'"H33G!"&"2"#D$G!%$!"30!A!$!""3$!H"4"!""#("!"9D"I33""3!2!43"""63!!!6"D!!!T!33aa!!
Electrical est I . contact
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OCTAVIA
Edition 12.00 S00.5111.54.20
K-
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23
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Test
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Electrical
contact
Edition 12.00 S00.5111.54.20
OCTAVIA
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T T The est R t . testers and aids
OCTAVIA
Edition 12.00 S00.5111.54.20
he
sender
est
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he
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23
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23
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Test
Test
102
110
Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
23
Edition 12.00 S00.5111.54.20
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7 % & & % & 4 & 3 3 " " " t b Y H C E H H C P y H E H C B A C H w G x Q & G v G 5 5 & % & & 4 & Y 8 1 ( 0 4 0 % & " # # " 7 & " & & "( " 5 2 ( 5 4 % & cP Y hF a !Q 7D G D e & "" " " p 2 H w x v 0 & 4 & & q #D X r" f # # 8 6 7" 6 " 3" & u u " & 4 & " & h # t 0" & 4 & & q" # ! " 4 % 3 & s 5 r a 2 8 !" 7" 7 y " y " " 4 & & s r a Y r f i 6 ! 0 0 a 5(" !" ! " ! %( () & " % & " p ! 4 % 4 & 5 5" 5" 5 " ) " ' &5 % 4 & 4 4 "( " " Yq i a " 7 & i S B H A B C I B T (" ( e ` ` X W Y5 V h X f( c Y W a V a f c Y g 2 (" (" 4 & ` X" W" W V5 d c Y W 8" 2 # 6 U ( ( ( !' ! % ` 6 X W5 W" V5 b( a Y 8 # # S R" B B Q Q H H I A E C B T D @ (5 ! %" " 4 7 4 " " # # # 8 5 7 ! 4 & & " # 6Q # 5Q ! ! G ! & & & 4 " " # 7 4 ! 9 #( # # 8( 5 ! & " 4 & 4 g 3 "( 2 # # ! ! ! " & & 0 & " # ( ( ! ! !" ' ! " &" P " &" &) "" " 5 # ' F %1 $ " ! " ' " " " " #"6 " # # D G " 1 F
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Testing needle
Test
testers and aids
sender
Test
. socket
55
Edition 12.00 S00.5111.54.20
OCTAVIA
e e i g p h f X 0 ' ' 4 3 d c 5 b E $ ' 0 # $ X 3 0 0 & #4 # 80 W5 8 5 9Y W 8 8 S G P T V T Q P D F W & & 2 4 3 8 3 A 5 4U 4 ' C 4 &0 2& 2 B& C % &6 4 &%# $ ' # ! B%Y ' 4 3 9 8 6 5 2 3B 4 0 a7%%B& ER %%& &% '& (@ 0 &(7 & % %0 (H ' ) $7B '(U% 1 " ' &%%@%%%% # # ! ` @ @ %7%%((%%B%% %(I%%% F& (D %B(%H
Continued for all models est 2-pin connector at . est
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OCTAVIA
Edition 12.00 S00.5111.54.20
. socket
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23
23
OCTAVIA
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Edition 12.00 S00.5111.54.20
P p P P s a b b v q r XP P p i X P S p i i p U S W W Q e q r X X PP X s i P P U p i S P U U P P Y s P A d i f e P p P P s P a b b v q rU Xp PS p i X P S p i i p U S Wr Wr Q e q rp X X Pp X s iW P P US p i S P U U P P YU s P A d h h f e P p P a b v b q rp u p Xr X ii P xx Pw p i S Yp P p p S S c p p u Q i6 x VY c p P U s s U p U P U q Q rs X X P s i P x P P s i x U p Xx PS Pi sTY P WS Q P s XY Pp iYW xB VP PY Ur s i U P x P P s P P qYtY q Q Tx y XgWW pU PTi X P6 VUr PWRW B sWTW UWW sRD UY i P P s i P x YY P P Wt q Ts p i P x S X P s i x iY x V p U s i P pi i s SP WP Y q q tw Ts Q U rWW P ug iY xW u p P p u p P Tx S YWW WW q x sWWWTr Wr uU iYW xYRD VY U S YP qRr H 6 A 5 6 7 B F IrT I y P Y b b arY `tW P eQ a WTY U w ` di IWr u P P U P x i ar `RT ` W RRRW ` w q IRRWR h WR W X X u P P P s P p i Y 6 `s v w a `RR bY W q Q q I R gYR a `Y eW e e ` e IRWY I cU XT P P U V U P S Y PT P U YRW Wf QWR Q Rf aTYRT `W bRWY dRT HWWD G 6EfWT 6YW BYW8 9TWRWr ES BW ARR 6W A EEr B 5 9 7 6 BWR 6W FT Fw 4 8tTRWR 8 0 2 ) 'E # !1 P SR TU WrR $W3 & fRC %W dW %tW@ " ! %WYW D@T (
Fuel Formation/Fuel Injection K K a as a Read measured value cold t
OCTAVIA
Edition 12.00 S00.5111.54.20
coolant
cable
as a
and
or
or
or
block
------------
cable
block
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23
w " ) 7 ( # # ( 7 4 ) " # ! # ) & ' V V X P P ) g e q' i h p( f s r6 p d c tG ( " ) ( P )" " ! ( ( ) & " & x " ) W ( ) & 6 ( ! 2 2 ( ( 4 ) ( w " 4 ) ) ( # " 6% & # x ) 6 ( ( '6 V v " x & ! P G Q 2 Ix ) 7 ) (' (# ) # ) 7 4 ( ) ( " ) x # ) " ' 5 "# ) w x6 )' "$" ( ( ( x ) ( ( F " " 4 B v e q i h p f s r p d c w "($ ) 7# (9 #$6' #' ( 7 4 ) " # ! ( # ) & 6 '4 V$V V X @66$ " GI T$6$$%$ ) 7 6 x ( g) e q) i h$7 u" f u s# r6 p' d c tP ( " ) ) ( # 7 P b (% ( &! )' 4'9 &$I " & x " ) W ( 6W ) & " ( ! W ( 4 7 2 2 % () (# 4# )$4 (b w "6 4# )9 ) ( #I " 6) & # x ) 6 # ( ( " " '( '# V( v %# V I ) 7 ( ) ( "6 x & ! ''$$ PY G Q 5I''$$ "" )6 x" )) "$# (# (# (1$'$$$' ( F w1% x1' )1' ( " " '' B v $'$$# q i' h u f u s r p d c "$$'I "1 &6 W' ) #' ( & 4g # 01 2''$' V$g V 94 5 "# )6 "9 "t 7 & 4 " ! " ) & ( 66 ( # " & ! 2I9 `# Q) a" X b) Y' "6 "' & W ( ) # ) ( & 4 # # 4 " 2'$$%$$$ VI V ( @ T @ T R G Q I" &# "6 5 !( #) & #" & 4' 7 H " 4 ( " 7 & " ! " B 8 S 3 %( A $( $" ( @ R 8 8 8 Q 8 8 P I" &! "'$' 5 !I #) &6$6 #10# &# 46 7' H''$ " 41$ ( " 7 & " ! " BY' 8 G 3 %( A $) 5$ "$$ ! & E B A 561' (# "4 7%$ &% "19 !9 "' &9 ( 6$16 6' " ) 'A @ %4 D% B 2$1' 8 8 59$6$% "e 7$6'%0 &#1 "! !'1'9C "'9 !$'1' !$6 &' 41$'g 6! 6# ) ( & " # # "'6$ ($t' "g ) '" 'F 3'' 2' $ )1I ($9 &9 " ! #1% #$U 01$%U ' %%$$ '$$$I '$%$$$9 '$ %$' 1% ' ' 9'9 ' $ %$$'
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23
50...100
104
Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
Edition 12.00 S00.5111.54.20
CG C E D F D A @ %( ( % 2% % 3 2 8% 76 63 5 1 96 4 & ( % " ' $ # !00 !!)' !!!B

23
If
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23
OCTAVIA
Testing brake light switch and brake pedal switch

In view of the fact that the fuel injection system operates with an accelerator pedal sender (potentiometer), which could develop a fault, the engine is governed for safety reasons when the brakes are applied. The control unit requires the brake light switch signal and, in addition, the brake pedal switch signal for this purpose. What this means, therefore, is that, if the brake is operated when the accelerator pedal is constantly depressed, the engine is immediately governed down to idling speed. If the switch positions are not clearly detected, this can result in unintentional governing of the engine speed. Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Procedure Read measured value block 0 km/h 000 6 000000
Read measured value block 0 km/h 000
6 000000
Read measured value block 0 km/h 011 6 000000 0 K
Middle readout = brake pedal switch
Right-hand readout = brake light switch Read measured value block 0 km/h 000 6 000000 0 K
If one of the readouts or both does not switch from 0 to 1: -
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Read measured value block, display group 006, engine idling page 01-33. Check readout in display block 2. Specification: 0 0 0 Slowly depress brake. Specification: 0 1 1 Both readouts should jump from 0 to 1. Slowly release brake pedal into rest position. Specification: 0 0 0 Both readouts should switch back again from 1 to 0. Test the switches or the cable connections to the switches. Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
Edition 03.98 S00.5111.52.20
f h g e d g ) @ ( 6 9 p r s p ` f g ) @ ( 9 q q p y p ` f g ) @ ( q p r p ` f A A 6 ) A 6 ) 6 5 6 @ ) Q @ D 7 B ) 3 wU @PD 66 B6 (U @ Q @ ( 9 D 2 ) 5 ' @ ( 6 G 3 3 H u E 6 9 B 5 6 ( F C E6 )6 (@ 6 B A ) ) @ ) @ ( 9 6 7D ( 6 7 D @ 6 3 3 A ED 9 ) 6 ) @ 5 D @ ( E 9 ) 2 ( ) 9 ( @ F( Fa 1' 6 ( 6 3 F C2 A 6a )9 ( @ @ 6 9 ) ' 6 6 5 6 ' ) ) 0a F F ( 6 ( 5 q C5 A06 619 )U (9 @P @ 9 @ ( 9 D 2 ) ) 5 @ ( 6 D 03 G 3 6P Bl ( D B ) 6 ) B P1HPQ sPPA pPP0YD A 3 D)111' 'F9 @6 B@v A( (9q DPs' 293 5P6 @PA 60Y5 '( 9P 6 ( 6 7( ' Q ( 6 ( 3P( Gt Pk 3 3 eI U1H6 `1j T6 f 'BP7 gPP01H11@7 gG88 @p3 @ q q i h pF s00 i @ x7 p h r r x p gY B 6 6 6 ( 5 6 D ( q i h89 h yw x2 p h wF G g80 t A018 A1 6 6 ' B1 6 q iP01C hCP80 h07 v( r3 p@ w@ 3 3 g @R q q i h p hR s s g7810 g E6 AH 6p (6 9 6 6 6 5 6 2 5 6 q7 q1u i117C GG F5 h0H r08181 p 80R9 e91 dD U) UP7 c( ` ` c70 a7 T f' S 60 61 ) 6 9 @ 6 3 G )000 ( 'P85 201 E &D 600 60810 ) 6 5 @ 5 6 @ ) ' 0 0u F 3 3 F 6UyI7 @FB 65 68U 67w QDq @A )gP 5P7D @t 6A 97 @ ) @ @ D 6 5 7 00 F'1@P7 F1C3 C6( A80010016 AQ D'p88 '3G 696 )99 5@v A( 6Pi' )p( 66 5818A 6H3 @ )5 Q6 @ D 76 B ) 5 ( 3@' P6 A1 6p 6a )@ 61H 9085 ' @ ) ( ' 2 & 6 6 ) 03 35R F H )) (5118C )( @ DR7 60 ' 5' 6 D 5 5 B 6 ) @ 6 7 07 3@ F F F 10 63 56 QV A1) 6( @) 6P8c 'c (8 5 ) ( ' 2 & 6 @ 79 0G FV 3 F F PP7 C6 66 90@ A @5 (H9 @ ) @ 6 D 9 ( 9 @ 5 ) ( ) ' 046 H H @F )16 @9 6) E 96 67 21u ( ' ( 75 9 5 6 9 ) @ @ D 5 ( 0709 F6 G85 30P F F 86 CI) A1PP40P @6 6G )U B9 (F 95 @5 6 6 ) ( 9P 6 7) ' 5 ( 5 ( 72 ' 2 & 0Q 09 3 $ % !I "877 #X IP1R 700 @ 0CP7 PP8P7 P P7 1F !0110 W7I000 H10 ' 2H118 110 0581010 P0741100801 70Y4880Y881100 01H10b00 0H0H H181000100 RP 0 01 @88P81117 000 C W P1RH7
900 900 Fuel Formation/Fuel Injection C K K l T The The
OCTAVIA
Edition 12.00 S00.5111.54.20
ment sender adjuster
est condition
testers and aids
3B
and
3C
The
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23
5 4 # $ # & $ # $ # D B $ # Dg B f f F e G f f 5 1 b $ $ 4 $ % % b $ ! 1 $ ! # % $ ! 4 % 5g ! $ )5 1 1 1 2 # 4 # $ $ & 5 d b $ % Eg 1 2 % $ % # ! % $ % % ! 2 b I# fG f G G W F 1 4 # 2 % x C B w # & $ % ! # % ' D D i$ BEE5 u q5 5 D r% pR Ta v 8 g E# ia 8 88 9C uE% q# s EEE5q r% r% p(% T$ E g DE# h3$ ia @E EEE# DE$ h i4 @ e $ gI G# f% f! % 4 B )2 %% $ $ b ! $$ 1 #E % $ ! 4 % ! $ $ $ # ) 1$""533) 13") 1 2% #E4 H %535 # !! $ 5EEEEF % % d 1"3) % $ )$ )! ) b""")" %# ! #5! $ #"" %c $E % % $ ! 4 # # 5 EC E! a b $""!35) % % a Y ` S V W Et) s2 $ )! """" Q T S R XE4 I E 8 E H y G! F % 4 # D 7 9 C B @ 9 8 1!c") 1"3 2 %2 $ 1 %% $ E $ % & $ 5$ 4 % # '2 ' 0 55""" 5 #"5 &! $ % ! % $ # ! (! ! 'R U 56"E""5")U333"")3EA"""!P"""P3")")c") E ") )
------------
23
------------
Electrical ment
Injection pump connector
connector at
and
and cable
Edition 12.00 S00.5111.54.20
OCTAVIA
h s p t r q i c $ # b ` $ g d E D # # # d a X% & & & $ & X a W $ & ' ' % Xe c & $ b c & & S G P 1 T V 1 T 1 Q P 4 F# 5 1 2 8e 6$ 7 3( f @ 9 7 0 ) A # & !! ! 4 1 8 6 @ 9 7 7( 3 f 0 # # e d a! W c be X X( 'U X W b# $ $ Ù X % Y W $ W X & S G P 1 T V 1 T 1 Q P UF 4 F 5I 1 2 82 3 0H ) 6 BR B @aEH 9a 7C A # & A D ! C # ! !! ( ) 4 1 2 8 6 B5 3 B @ 9 7 0 ) (U # '( &H % $ "! ER ! D A F I 5 !! ! H
If Continued for all models If the est est 10-pin connector at 10-pin connector at the the . . t the the est est
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OCTAVIA
Edition 12.00 S00.5111.54.20
. socket
. socket
the
the
the
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23
23
OCTAVIA
------------

------------
Edition 12.00 S00.5111.54.20
f h g e d ( ( # & # $ & # Q h % % g d y c c U ! c # # ( # ( ( # e ) $ ! y U # ( # ( e c$ )! ex $ ( # # H e ( # ( !! # ! & ) # 0 % $ X T y ( ( # & # $ & $ # ! % % A 5 F @ r 1 # ( ( # & $ % 0 $ & & $ # ! % % % g0 v y # $ H ( ( & # $ X V u % $ & & % % c) U 0 I v ( @ 2 # $ ) ) & ) & a 0 v v R y # $ H ( ( & # $ T V u % y # U $ & H $ & & # ( $ # ! a % %"! %! gH v y #'''"" $ H ( ( & # $ X"2! Vc uc % x"'! x'"' $' & & # ( $ # a %! % % y c% % # $ H ( & ( # v' v TH V u % d 2# c U" ""x e $ # ( e ( & f2 ic R"! v % 0 Y $ )e #% e I $!c H && #2 ) !% ) 1 %''! V" u t % A 5 E" 5 @ 4 5 F r G9 G # # ! S0 S Q P R Xv qR h R T T q Q P h R G e & $ S Q P P i hg R P g$ V G"' b 2 I"'x''" Ix ) e ( S' P% f# gd d Q!d P! T! R % 0 G #" S S a!I `'x P X X X X Q P R R G! v G U''2 I'"I &'"% v 'x & H & & S" S " Q!'"'!%! V#& 0$ PT T22! R 0 E!i) D!q1 5p 5"R CvV @ @u C!") A 8 F'x''#! 3t (c ) # ( # ( 6 6 1V 2"" $"q $xq )! &2!W (! & !W $ !# # "$ %I 05u %""Bvv %'T '& '2 0 7!"c2V #v &v T) ( &22!"'xt x!'"'xv (""'2I #!" &Y""21 #""2% $R d% &'i ''Y'!$ $ # !'2"i "gdTv %7#2! %22!w'') %2 & ' v! R c$ I 22!'"""u "!9" 4#!! V ' !!9"'"") Cst 2C'' 2) % % 'I W'"R % )1 '2"&
100.0 0.0 000 010 Fuel Formation/Fuel Injection K K K K T The he
OCTAVIA
Edition 12.00 S00.5111.54.20
sender
est
accelerator
testers and aids
------------
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23
f h p i g 4 Q R Q I 1 3 8 e d Q ` C C b c D C C 4 ` 2 A A a 4 ` 2 A A a C 4 ` 2 A a 3 8 4 ` 2 A a C 8 X V % # ! # # W % % # ! ( # ! % % # % ( " ' 0 ) ) ) T D B R S Q D C H G I E D Y C ") @") 4U 4 4 4 4 2) A 8" 1" 7 5 @ 4 4 4 4 4 2 6 8 1 7 5 4 4 4B 4 4 2 8 6 1 7C 5 3 4 4 4 4 4 2 3 1 6P 1F 7C 54 % # ! ( % & #B ! # ! " " " ' $ 0 ) ) ) "
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23
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Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
Fuel Formation/Fuel Injection Test the wiring between test box and connector of sender for open circuit according to the current flow diagram: 6-pin connector at wiring loom, contact 1 2 3 4 5 6 -
23
Test box V.A.G 1598/22, socket 24 23 12 25 8 11
Rectify any open circuit or short circuit in the wiring.
If no fault is found in the wiring: Replace engine control unit (J248) page 23-20.
Models 08.98 - Remove bottom part of dash panel Body Fitting Work; Repair Group 68. K-
Unplug 6-pin connector for accelerator pedal position sender (G79).
Test resistance of accelerator pedal position sender: not depressed not depressed not depressed depressed depressed Accelerator Contacts 4+3 2+3 5+6 1+6
Specification 0.6...1.4 k 0.6...1.4 k 0.6...1.4 k
not depressed
0.6...1.4 k
Replace accelerator pedal position sender (G79).
Edition 12.00 S00.5111.54.20
------------ 23-48.1 ------------
23
Fuel Formation/Fuel Injection If the specification is achieved: K-
OCTAVIA
Test voltage supply of accelerator pedal position sender: 6-pin connector at wiring loom, contact 2 + earth 1 + earth 1+6 2+3 Specification approx. 5 V approx. 5 V
approx. 5 V approx. 5 V
If the specification is not achieved: Connect test box to the wiring loom to the engine control unit page 23-19.
Test box V.A.G 1598/22 K Test the wiring between test box and connector of sender for open circuit according to the current flow diagram: 6-pin connector at wiring loom, contact 1 2 3 4 5 6 Test box V.A.G 1598/22, socket 11 8
23 24 12 25
Rectify any open circuit or short circuit in the wiring.
------------ 23-48.2 ------------
Edition 12.00 S00.5111.54.20
OCTAVIA
Fuel Formation/Fuel Injection .
K Test the wiring between test box and connector of sender for open circuit according to the current flow diagram: wiring loom, contact .
Edition 12.00 S00.5111.54.20
2 6 7 ` 3 0 Y T $ ! Q I Q E G 6 D 1 ( 5 1 2 4 ( 3 1B 20 ) 0D '8 0 )B (7 ' 7 "V 0 ! " & X#H %! C 8 $ ! a# ) S b " ! P C 9@WU @A R@ SH F A S
23
1 open circuit or short circuit in the no fault is found in the wiring: engine control unit page
------------ 23-48.3 ------------
23
OCTAVIA
------------ 23-48.4 ------------
Edition 12.00 S00.5111.54.20
OCTAVIA
Final control diagnosis AC compressor control
K-
Edition 12.00 S00.5111.54.20
P R Q I H @ ' 6 8 ' 5 B & @' G09 '' '9 ( D ( 9( ' ( 6 ' 6 9 ( 8 D B5 BF C 09 1) 6 ( 1 6 ( ' B & 7E 6)E0 @ 6 5 8 ( ( 6 ' 2 5 1 9 ( ' 9 ) 4 3 & A % ! $ "5 # ! A0 ) ) 0 ) 0
additional
23 and to air
The AC compressor is switched off by the engine control unit in the following situations: when accelerating from a low speed (recognised by change in angle and accelerator pedal position sender and from the vehicle speed signal) in the emergency programme (emergency mode) if the coolant is hotter than 120 C for about 6 seconds each time the engine is started l Air conditioning o.k. l Air conditioning switched on l No fault in fault memory t t and Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Hand-held multimeter (e.g. V.A.G 1526 A) Adapter cable set (e.g. V.A.G 1594 A) Test box V.A.G 1598/22 or V.A.G 1598/31 Hand lamp Initiate final control diagnosis and actuate AC compressor control page 01-18. AC compressor must stop within 5 seconds (visual check with hand lamp), and then run for 5seconds and stop again. If the AC compressor does not switch off:
-----------------------
$ x a " w E w w U y Y D E u X E E E E v $ E u E D E E E E t E E B D E r E U q E E E C $ Y Y Y E E B H P i g ' &U i P ' p P ' 0 P 0 i G P g ' & ( d h % b H 0 ' & 0 g c P P & 0 F d d $ Y Y X s ED W S U C S E S V U C T S a ! 0 & G ' 7 R 6 ` 9 8 6 Q H P( Pb ' 0b I &f 0 G 0 1 ' & (b F 4 5 4 2 ) % $ b b ( E b h C e h Dh ( $ Ef B 0 1 ' & 7 6 ` 5 4 2 9 8 6 ) % Y Y X S ED W U ( S E3 S V U @ ( 3 TQ S 0 & G ' 7 R A A 9 8 6 Q H P PC ' 0 I & 0 G 0 1 ' & ( F 4 5 4 2 ) % $ $ D C E ( 3 3 D@ E B ' & 0 1 7 5 4 A 2 A 9 8 6 ) % @ C $ 3 Q 3 ( # "3 ! C ( @ C 3 (
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23
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16
Edition 12.00 S00.5111.54.20
contact
contact
OCTAVIA
OCTAVIA
Read measured value block 900 rpm 0.0 %
Fuel Formation/Fuel Injection 2 18.4 C
111
Edition 12.00 S00.5111.54.20
& 1 ( ) 2 0 ' # "$ ! ! $ # " ! ! " "

23
K Specification in display block 3: X X 1 (AC signal) If the specification is not achieved: Connect test box to the wiring loom to the engine control unit page 23-19. . Test the wiring for short circuit to positive and to negative and also for open circuit. . contact 48 Current Flow Diagrams, Electrical Fault Finding, Fitting Locations binder Rectify any open circuit or short circuit in the wiring. . Test the wiring for short circuit to positive and to negative and also for open circuit. . contact 49 Current Flow Diagrams, Electrical Fault Finding, Fitting Locations binder Rectify any open circuit or short circuit in the wiring.
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23
OCTAVIA
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Edition 12.00 S00.5111.54.20
OCTAVIA
Read measured value block 0 km/h 000 Read measured value block 0 km/h 100
000000
000000
K-
Edition 12.00 S00.5111.54.20
@ A B 9 8 6 6 4 " ' ! " # 2 5 5 4" 3 "( " % 1" ( ' " ' 1 ( ( ( " ! % 2( 2 0)0 1 1 1&& # $0 $ $"
23
This signal is used to avoid overrevving and load change jolts when the clutch is released, and is required for the cruise control system. t t and Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Hand-held multimeter (e.g. V.A.G 1526 A) Adapter cable set (e.g. V.A.G 1594 A) Test box V.A.G 1598/22 or V.A.G 1598/31 condition l Fuses o.k. Read measured value block, display group 006; engine switched off page 01-35. Specification in display block 2: 0 X X Depress clutch. Specification: 1 X X If the specification is not achieved: End output (function 06) and switch the ignition off. Unplug the connector of the clutch pedal switch page 23-2, Overview of fitting locations. Connect the multimeter for resistance measurement between the contacts of the switch. Specification: Clutch not depressed: max. 10 Clutch depressed: If the specification is not achieved: Replace clutch pedal switch (F36). If the specification is achieved:
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v x y w u ! b Y ` s t r q E i 0 ' & 0 U R f f & 0 T e T c c $ b a a " 0 & I ' 7 W 6 d 9 8 6 V G I 0 1 ' & SC U &C R I I ( ( 5C F Pp 4 2 ) % H T P Q Q H Q C Q ( D D EQ E C h g $ C B 0 1 ' & 7 6 d 5 4 2 9 8 6 ) % 3 3 ( V @ c c ( X b a ` Y 0 & I ' 7 W A A 9 8 6 V S U & IC 0 1 ' & G$ R I I ( ( T 5 4 2 Q ) % P F P Q H D 3 ( D E E C @ 3 $ C B ' & 0 1 ( 7 5 4 A 2 A 9 8 6 ) % @ $C 3 V X # " ! $ 3 ( 3 C 3 ( @
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23
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at contact
at contact
Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
23
Edition 12.00 S00.5111.54.20
------------

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P 2 & % 1 & 1 2 % & % 1 % 1 % $ # E0 &3 %% $1 " ! ! 1 % f # e D% # C 7 2 % 1A % 3 ! " & ! 1 3 C A 6 # # W $ & " % ) 1 % 1 $ % s e i g 7 2 1F 1 1 $ % 1 1 w 3! 6 A & 1 % % 1 & ! # 7 2 1 " & # 4& 7 7 1' 3 & % " 9 ! ) ! # # A @1 P 1 & " 9 % % ! 1 & " %3' 4 )E 9 '% ' 3 e A C # & ! 1 & % 6 # # E' 4 $ & " $ % % $ % f3E i e # & "# ) 1% $& 7 &H "033 9 !@ 1 ) & '! ) & y # # A C # b3 G W R S `4 c3 c E E 1 1 ' f f d3D 53' e!@ i" x1 s eG g g x d4 5 s e c33 u 1 7 $ " & v f p D d 5 g e cI $ & ! " & f d3 5 5' tG s8 e 5 D A # c33 q 734 7 $ ) & f @ d! 5# 5333 rr g3' eD D) # c 1 f f 63303 d i 5 e e p 5 i i i c0 c 2'' 7 1 & F ! ! 3" f f A# w 5 d33 C gE e b a!C G") G3330 U33y H0& Y7 W) W Y H# G# H G H'7 U& Sd Àh TH Èr& Q! P1' 74 13 1 " C # H 7 $ ! % 1 & ! 1 1 C A A D # 7 $G %) %F & %0 ' 1E % & ! 9 ' 1 % 1 ! 1 #@ 8h% 7334 2E3' $0 %A &9 1 $ &'E %@3 EE' G EE 1 " ! ! 1 ' % 3! 6 ' 5 R 4 2! E' !! )Y (3 h & % $ " ! 'E3 ! ' 1Y8 ! 'EE' 3! #'3E # # E 0G ' TEI0 EE8'E03 ! IIE 3XI EE3V Y 3T 4 I 3 'V' 0 '3B@3 'h3 3
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23
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000
000000
Have a second person operate V.A.G 1552.
Warning!
condition
and
Edition 12.00 S00.5111.54.20
OCTAVIA
Fuel Formation/Fuel Injection -
Edition 12.00 S00.5111.54.20
4 4 8 6 7 9 5 3 0 1 ) 1 & ! ' # " ( 2 ! $ ( # " & ! ' % # " $ % $
Diode test lamp must flash (about 4x for each revolution of wheel). Note: Ensure that the right front wheel does not rotate. If the diode test lamp does not flash: Test the following cable connections for short circuit to positive and to negative and also for open circuit. . contact 51 3 Rectify any open circuit or short circuit in the wiring. . Connect diode test lamp between socket 1 (earth) and socket 20 (vehicle speed signal). Switch ignition on and rotate front left wheel by hand. Diode test lamp must flash (about 4x for each revolution of wheel). Note: Ensure that the right front wheel does not rotate. If the diode test lamp does not flash: Test the following cable connections for short circuit to positive and to negative and also for open circuit. . contact 20 3 Rectify any open circuit or short circuit in the wiring. If no fault is found in the wiring: Determine all the users of the vehicle speed signal (e.g. radio, air conditioning, etc.), separate the connection to the dash panel insert one after the other and repeat the test until the cause is determined.
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23
23
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Edition 12.00 S00.5111.54.20
OCTAVIA
Edition 12.00 S00.5111.54.20
E F D D C 3 1 7 5 6 2 B 9 8 6 0 ) @ 3 1 7 5 A4 2 A4 9 8 6 0 ) @ ( ! ( ! & ' %G $ G 8 " " # " # ! ! "

23
and
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Test box V.A.G 1598/22 or V.A.G 1598/31
The engine speed signal is required for the rev counter and for the air conditioning. If an automatic gearbox is fitted, it is also required for calculating the shift points. The signal shape which is generated by the engine speed sender (G28), cannot be analysed however and it is therefore first of all processed in the engine control unit. The engine speed is determined as follows:
Read measured value block, display group 001; engine idling page 01-38.
Briefly operate full throttle.
Read measured value block rpm 5.6 mg/H 1.480 V
1 87.3 C
Specification in display block 1: The current engine speed must be displayed (evenly over entire range). This engine speed display must agree with the revs indicated on the right counter.
Connect test box to the wiring loom to the engine control unit page 23-19. .
Test cable connection from rev counter to contact 6 of test box for open circuit Current Flow Diagrams, Electrical Fault Finding, Fitting Locations binder. .
Test cable connection from rev counter to contact 27 of test box for open circuit Current Flow Diagrams, Electrical Fault Finding, Fitting Locations binder.
------------
------------
6 % % % 9 # 9 ( ( ( 9 $ ( ( ( # ( # 1 P E F $ $ % ( 1 !) ( $ ! $ % ( ( ! I ) 6& !( $ (&! ( % 6 ! # ! ( 1 % 22 ) 0 % F P E E SI $ (# ! 9 ( ( 1 # `( P 0! 2 E 2 8 % ( "( ' x s v u( h h s&6 v( q p e i e i p s t& q p f r r d c ( $ ( S 6 ! ) T (# %'# S (' % 99 6 I 9 ( ( ( 6 ( I & 2( ( % # # ! S6 2 %9 %"0 (9 ! ( ( I # ( ( 2"g ) (` %'B !( (! !! #( !9 ( ( ! 8 9 % I &' ) 2 6'4 !&4B 19 6 % 9 b a ` Y A $" ("&& 6 40 S"&4 %% S (1 %& 9% && 6 I 9 ( ( ' ( % (( % ! #R % '2 ) 0&' X U $7 6 !y !' S (e 9# 9U ! # ! '&1 U3% W# V F U " $'"&3 49 S!' ( %"I (&g7"( %3"# 9( ' 6 '&W I 9 % &% 2( ) T S9 (&0& ( (C (# ( (& 6B&( % 9 9 % # I 9 0% 2 v ( % # # ! 0 7( %% %( (6 !6 # ( ( I # ( ( S% # 2&9 ) 6 3&( ((&BB" %6 !i ! 12 (&6 ('&77 ! 8# % 9 ! # ( I 2#& )"! 2B B6 $ %' ( 6 9"2 ! ( 6 8 ! ( # 0 @f ) $# (! !w I6 1 (&3 #( 6' (f #&9 ( I ( # ( 9 )% ) 0 ) "6 C 2 ! ( I 9 9 D ! ( I) 6i %( !) I9 (&9 ! %g % '# ! G&"I P&3(fg H&( Ffg E' ) ) # ( C $&3" ( # # % ) $&'" !#"# (! %1 $ %2 $ (9 6''' 9& !" (&"# '% 6 8 ! ( # 1 2( 0( @% )&'3# ) A% 3% 46 6'% !6 $ %% ( #2 !9 #"! (9 ("&( #&Q ( 1 % % ! # & )% 2! 0 ) 5! 3&# '&3" "' "''&'#&Q2&7"('3&"&"&9"'3&333'''&&"#'&&"&7&"&"73%&&&'&&9&&'&&''''"B"&&&&&&33""3RR"" 5&'"'Q ' "( &"
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23
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control
01
condition
and
1552
Edition 12.00 S00.5111.54.20
OCTAVIA
038906012F 1.9l Coding 00001 038906012F 1.9l Coding 00001
R4 EDC G000AG 2813 WSC 01234 R4 EDC 0000AG 2813 WSC 01234 HELP
K If G000AG is displayed, cruise control system is activated. K If 000AG is displayed, cruise control system is deactivated. K Readout in display: -
Edition 12.00 S00.5111.54.20
) 0 0 ( ' % # & " #" ! $

Readout in display (example): Enter 11 for the function Login procedure and confirm entry with the key Q. Enter code number as specified in the table below and confirm entry with the key Q. Activate CCS Deactivate CCS 16167 11463 End output (function 06). Conduct a road test.
OCTAVIA
23
cruise control
With the exception of an operating switch, the CCS does not have any separate components. All the functions are performed by the engine control unit. The minimum vehicle speed for the cruise control function is 30 km/h. t testers and aids
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Hand-held multimeter (e.g. V.A.G 1526 A) Adapter cable set (e.g. V.A.G 1594 A) Test box V.A.G 1598/31 Test condition l Fuses o.k. T -
Read measured value block, display group 006; engine idling page 01-35.
------------
------------
v x y y w $ u Q s " h t r ( ! b $ d p p b f c $ d p p b $ i $ g h b $ d e b f 0 Cq F a 3 Y `f @c 4c V 0 4 V 0 C 4 2 X 1 3f W 6c B 0 4 2 0 @ A V V 2 0 1 U 1 ( T S I & H H ( 3 3 5 " I E 3 ( H6 6 7 7 B 0 8 G D5 @ 2 0 C A @ @ E 2 0 4 2 77 7 7 7 7 F ) 9 1 1 6 6 # Q H (6 ' ' Q " & # $" P " H P % #g $ ( 6 " ! P H ( " g " R H 3"
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23
------------
000000
000000
3.
4.
000001
000000
100011
001011
000011
010011
000111
Edition 12.00 S00.5111.54.20
OCTAVIA
i i g F V T i T i d ! R iI d S F Q R F F Q F F X F @ 6 ) %i & 5 ) 8 ) @ 5 4 q v % 6 @V s x wH u 19@ t y 1 r d V X F ! P(V i f Q X V P 2 i p I H e W Q X g f Q ! " d c P T " d P GP F G S V C Y Y ! G S a R b G a F I G HA S Q C R Y Y 5 IP G HA S QP( X G S R G S V IP@ G H H1 QP T F U A G S R( ' IP Gh H'' H QP(93 C D F A 5 @ &" ) % (Pi ( ' # # 09 $ ' 3 81 4 ) ) 6 & 5 4 ) $ 7 # 2 # 'W 0 'P $ ! ! E( i B % 'PP3'EBEEBcc B " P " "
T connector at V at contact connector 5 5
------------
OCTAVIA
Edition 12.00 S00.5111.54.20
K-
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23
V u u 6 5 2 6 2 & 6 A 6 4 & f c d i & 6 2 u V v Q' 9 6 ) & 2 % 2 & a& & % 2 @ v D ( B &I 6) )0 44 & & % % 5 ) & % 6 ) 6 5 2 6 1 1 ' @ # B 6& &) && B 6 2 & A % 6 % ) 6 & & ' (D @ @ # & A ) 0 6 5 2 6 2 & 6 6 & w s4 u ( 21 &% )A %6 & 6 4 6 2 4 2 6 2 4 6 5 2 6 '2 D& #6 6y &) &0 24 2 & a t Ue (' G s T w s F D 6 5d 2d 6 2 6 B2 &2 2& A' 5 0 6 5 6 ) 2 & 6 6 2 4 1e & '& '0 (A @ $ ( 7& I 9 2 6 2 6 A ( q c d 2 6 ) & && 5''Q# S6 )1 )3# %4 & 9 ) & & & 4 ) 5 % ) '4 (& D6 D4 @ ( @ G @ t s8 U38 G T w s A & & & ) % & 0 ) t4 UeQeg GA GeQ TQ x4 w' sg G Peg D @ r B B A & & & 5 & t1 U3'3733 G@ G T v& u& s3'7 PQ6 @ ( @ q p%3 4' ''8 1 f' i8'3 i f 4# 313' b 68' 53 2 %3' 2 & @ #A & 5 ) ) 6 2 9 ) & 0 2 ) & 62 2'a &6 )1Q3 42 % % a 'i ' (4 ( B&3 B''# B8'83' &%' 6& &6 & &'Q3' 61 6'1 2Q' ) 6 5 4 2 1A & A 4 6 % & 'd @ ( 3% ` & & 5 #6 6 2 6 5 & 4 6 ) B8'3'# &y &'' %4 %& )1 2 44 5 '& @ GQ V V B1'38 & & & % & % S % & & 6 U2 GW'8 T34 F ( Q A& && )4 &4 &3 S6 5 6 & 2 % 6 5 2 % 16 6 2 & 1 4 '6 '6 (@ 3'X ('7# #4 & 6633 2D &S' 4Q& )''7'33 )i 6 2 & % 6 6 2 4 A 5 0 4 & ''38& (4 ( Q 9 2 & & & 5i % H Dg G I P #'6 #( 2@ 6C 2) & 1% & C 2 & 5 ) ) % 'c F6 H8'% F4 GQ# D @ @ ( 8) E# #A 6&38 2& B' && )'Q''8Qhg 9'31 4eQ% 6'13Q' 5Q'333'' %E8Q''7 2g' 6'' 2'1 4 & 4 12 6 & 1' ' (' ( @ 671' &88'18' 51 &1 ) 4 0 2 0 0 ) 131 1 B1Q13Q''8 94 )6 A2 %&7 )''3eQg81 2'''1 10 & % ( @4 $ 36 73% 8E "' !e '#3# 3'31888'' Y# 73Q3'R 7 31 83'18 '' # 'g' 3''8'
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23
------------
condition
readout
not
and
1552
Edition 12.00 S00.5111.54.20
OCTAVIA
OCTAVIA
Edition 12.00 S00.5111.54.20
& # ( ( 3 6 % 8 # 6 2 ) ) 7 5 @! 9 1 % # # $ " 0! 4' ! ) ! 0 '

23
-----------------------
A E C D D F B
23
OCTAVIA
Servicing intake manifold flap 08.97
1 - Intake manifold 2 - 10 Nm 3 - O-ring Replace 4 - Intake connection With exhaust gas recirculation valve and intake manifold flap 5 - 10 Nm 6 - Gasket Replace 7 - Connection pipe To exhaust manifold 8 - 25 Nm 9 - Vacuum positioning element for intake manifold flap 10 - Intake manifold flap changeover valve -N239 Testing page 23-57 The intake manifold flap is closed for about 3 seconds when the engine is switched off and then opens again. This reduces the engine stop jolt. Testing intake manifold flap changeover page 23-57. 11 - Vacuum supply From vacuum pump
------------ 23-56 ------------
Edition 03.98 S00.5111.52.20
OCTAVIA
Edition 12.00 S00.5111.54.20
9 A @ 8 7 5 & & $ 6 ! 5 ! 4 4 3! 2 !! ! ' $ 0' ' & ! & 0 ' $ ' ! 0 1" 1 #' () #0% ) ) # ## )%
23 i
t t and Hand vacuum pump (e.g. V.A.G 1390) Test box V.A.G 1598/22 or V.A.G 1598/31 Hand-held multimeter (e.g. V.A.G 1526 A) Adapter cable set (e.g. V.A.G 1594 A) Current flow diagram condition l Fuses 29 and 34 o.k. Start engine and run at idling speed for about 5 seconds. Switch ignition off. Observe positioning lever at intake manifold flap (2nd person required). After the ignition is switched off, the intake manifold flap must close for about 3 seconds, then move back into its original position. If the intake manifold flap does not switch over, perform the following inspections: Inspect switchover mechanism of intake manifold flap by operating the linkage by hand. It must be possible to easily move the intake manifold flap. Ensure the vacuum hoses are correctly attached and connected as specified in the hose diagram page 23-59. Detach vacuum hose at vacuum positioning element for intake manifold flap. Connect hand vacuum pump to vacuum positioning element. Operate hand vacuum pump. Intake manifold flap must close.
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23
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Edition 12.00 S00.5111.54.20
OCTAVIA
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OCTAVIA
Edition 12.00 S00.5111.54.20
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23
23
OCTAVIA
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Edition 12.00 S00.5111.54.20
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13 12 10 11 Vacuum 9 3 2 1 Vacuum 3 2 1 Pressure unit for charge pressure control valve part of turbocharger, cannot be replaced separately white connection points toward charge pressure control solenoid valve -N75 models 08.97 Vacuum unit models 08.97 Vacuum Vacuum o o air o air 0 0 control solenoid element element recirculation recirculation
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OCTAVIA
Edition 12.00 S00.5111.54.20
23
OCTAVIA
Glow Plug System
28
Testing glow plug system

Testing operation
Special tools, testers and aids required Hand-held multimeter (e.g. V.A.G 1526) Current flow diagram Test conditions l Battery voltage at least 11.5 V l Diesel direct injection system control unit (J248) o.k. l Strip fuse for glow plugs (S 132) o.k.
Test procedure KSwitch off the ignition. Unplug connector -1- at the coolant temperature sender (G62) -2-.
Note: When the connector is unplugged from the sender, the cold engine state is simulated and appropriate glow plug heating operation is carried out when the ignition is switched on.
Unplug the glow plug connectors from the glow plugs. Connect the multimeter for voltage measurement to a glow plug connector and to engine earth. Switch on the ignition. approx. battery voltage should be displayed for about 20 seconds.
If no voltage is present: Rectify any open circuit in the wiring or short circuit. Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder During the simulated glow plug heating operation, the glow period warning lamp (K29) should come on.
Edition 03.98 S00.5111.52.20
------------ 28-1 ------------
28
Glow Plug System If the warning light does not come on: -
OCTAVIA
Test glow period warning light page 28-2.
Testing glow plugs

Special tools, testers and aids required Diode test lamp (e.g. V.A.G 1527 B) Hinged wrench for glow plugs (e.g. 3220) Test condition l Battery voltage at least 11.5 V Test procedure KSwitch ignition off. Unplug glow plug connectors from the glow plugs. Connect cable of diode test lamp to battery positive (+). Switch ignition on. Connect test prod of diode test lamp to each glow plug one after the other. LED comes on: glow plug o.k. LED does not come on: replace glow plug. Use hinged wrench, e.g. 3220, for removing and installing the glow plugs. Tightening torque: 15 Nm
Testing glow period warning light

Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Test box V.A.G 1598/22 or V.A.G 1598/31 Adapter cable set (e.g. V.A.G 1594 A) Test condition l Fuse 29 o.k.
------------ 28-2 ------------
Edition 12.00 S00.5111.54.20
OCTAVIA
Glow Plug System -
Final control diagnosis Glow period warning light -K29
Edition 12.00 S00.5111.54.20
K Readout in display: The warning light must flash. If the warning light does not flash: Test box V.A.G 1598/22 Test box V.A.G 1598/31 Continued for all models Switch ignition on. Warning light must come on. If the warning light does not come on: -
28
Initiate final control diagnosis and operate glow period warning light page 01-18.
Connect test box to the wiring loom to the engine control unit page 23-19.
Use an adapter cable to connect sockets 1 and 41 of the test box.
Use an adapter cable to connect sockets 1 and 42 of the test box.
Rectify any open circuit or short circuit in the wiring Current Flow Diagrams, Fault Finding, Fitting Locations binder. If the warning light now comes on, but not during final control diagnosis: Replace engine control unit (J248) page 23-20.
------------ 28-3 ------------

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Service

Workshop Manual OCTAVIA

Service Department. Technical Information

Printed in Czech Republic

Edition 05.97 03.98 02.99 12.00 09.03 01.04 08.96

Article Number S00.5111.51.20 S00.5111.52.20 S00.5111.53.20 S00.5111.54.20 S00.5111.55.20 S00.5111.56.20 S00.5111.50.20

Contents next page.

01-18 01-18 01-21 01-23

01-1 01-1 01-1 01-2 01-5 01-8

01-24 01-24 01-26

01-28.2 01-28.2 01-29 01-38 01-46 01-49 01-51 01-52 01-58

23-22 23-22 23-24 23-25 23-26 23-27

23-28 23-28 23-29 23-30

Edition 01.04 S00.5111.56.20

Glow plug system

28-1 28-1 28-2 28-2

Edition 01.04 S00.5111.56.20

Technical data of self-diagnosis

Edition 12.00 S00.5111.54.20

------------ 01-5 -----------01-1

08 Read measured value block

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

l Earth connections at gearbox and on left below battery o.k.

Edition 12.00 S00.5111.54.20

Test of vehicle systems Enter address word XX

Edition 12.00 S00.5111.54.20

038906018BQ 1.9 l R4 EDC G00SG 2112 Coding 00002 WSC 01234

Coding 00002 Coding variant of control unit WSC 01234

Data status (software version) of control unit

038906018GM 038906012H 038906012F

08.98 04.99 05.99 07.00 08.00 08.03 08.00

For current control unit version - spare parts catalogue

------------ 01-4 -------------

Edition 09.03 S00.5111.55.20

Test of vehicle systems Select function XX

K Readout in display: For further procedure Repair descriptions.

Interrogating and erasing fault memory

Test of vehicle systems Select function XX

Edition 12.00 S00.5111.54.20

------------ 01-9 -----------01-5

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

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

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

For vehicles 08.03

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

Test of vehicle systems Select function XX

Test of vehicle systems Select function XX

Test of vehicle systems Fault memory is erased

Edition 02.99 S00.5111.53.20

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

Explanations concerning the types of faults (e.g. Interruption or short-circuit to earth):

Line interruption/short-circuit to earth Supply voltage

17564 17565 17566

Short-circuit to positive -G71 defective

Line interruption or shortcircuit to earth -G71 defective Line interruption or shortcircuit

Line interruption or shortcircuit

------------ 01-8 -------------

Open/short circuit to positive

Engine preheater does not operate

- Test intake manifold temperature sender page 23-25

Edition 02.99 S00.5111.53.20

- Check fuel system

Engine stops Misfiring

Sender plate of engine speed sender bent or loose -G80 faulty