Manual Skoda Octavia 1,4 55kW

Service
Workshop Manual OCTAVIA

1.4-ltr./55 kW Engine, Motronic Fuel Injection and Ignition System
Service Department. Technical Information

S00.5133.50.20 Edition 03.01
The Workshop Manual is intended only for use within the koda Organisation; it is not permitted to pass it on to third parties. 2001 KODA AUTO a. s.
Printed in CR
Service
Supplement Overview for the Repair Manual OCTAVIA
1.4 l/55 kW engine, Motronic Injection and Ignition System
Replaces the Supplement Overview - Edition: 03.01
Supplement
Edition: 04.02
Edition 03.01 04.02
Subject
Basic edition Changes for the engine BCA
Article Number S00.5133.50.20 S00.5133.51.20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Table of contents next page
This document is copyright protected. Any use of this document without the agreement of the copyright owner is forbidden 2002 KODA AUTO a. s.
Printed in Czech Republic S00.5133.51.20
OCTAVIA
01 Self-diagnosis
Contents
Service
Page
General information about the self-diagnosis .......................................................................... - Properties ................................................................................................................................. - Technical data for the self-diagnosis ........................................................................................ - Connecting up the vehicle system tester V.A.G 1552 and selecting the address word for the engine electronics ......................................................................................................... - Interrogating and deleting the fault memory ............................................................................. - The fault table ........................................................................................................................... - Actuator diagnosis .................................................................................................................... - The readiness code .................................................................................................................. - Reading the readiness code ..................................................................................................... - Generating the readiness code ................................................................................................ - Reading measured value blocks .............................................................................................. - Reading measured value blocks, display group 001...009 ....................................................... - Reading measured value blocks, display group 010...029 ....................................................... - Reading measured value blocks, display group 030...049, 099 - lambda regulation ............... - Reading measured value blocks, display group 050...069 ....................................................... - Reading measured value blocks, display group 070...079 ....................................................... - Reading measured value blocks, display group 100 ................................................................
01-1 01-1 01-2
01-4 01-6 01-8 01-29 01-31 01-31 01-32 01-38 01-40 01-46 01-52 01-60 01-66 01-67
24
Fuel preparation/injection
Repairing the fuel injection system ........................................................................................... - General comments ................................................................................................................... - Safety measures ...................................................................................................................... - Cleanliness regulations ............................................................................................................ - Installed location of the individual parts of an engine with engine identification characters AXP ........................................................................................................................ - Installed location of the individual parts of an engine with engine identification characters BCA ........................................................................................................................ - Removing and installing parts of the fuel injection system ....................................................... - Disassembling and assembling intake manifold ...................................................................... - Disassembling and assembling the fuel distributor with fuel injection valves .......................... - Disassembling and assembling the air filter ............................................................................. Checking components ................................................................................................................ - Checking the lines using test box V.A.G 1598/22 .................................................................... - Checking the throttle valve control unit (J338) ......................................................................... - Testing jet formation and tightness of the injection nozzles ..................................................... - Checking the fuel pressure regulator and holding pressure ..................................................... - Checking the intake system for leaks (unmetered air) ............................................................. - Checking the intake air pre-warming system ........................................................................... Checking functionality ................................................................................................................ - Checking the lambda probe and lambda regulation before the catalytic converter ................. - Checking the lambda probe and lambda regulation after the catalytic converter ....................
24-1 24-1 24-2 24-3 24-4
Page
Checking auxiliary signals ......................................................................................................... - Checking the speed signal ....................................................................................................... - Checking the databus (CAN bus) .............................................................................................
Engine control unit ...................................................................................................................... - Checking the power supply to the engine control unit .............................................................. - Procedure if the voltage supply is interrupted .......................................................................... - Replacing the engine control unit ............................................................................................. - Coding the engine control unit .................................................................................................. - Adjusting the engine control unit to the throttle valve control unit ............................................
24-24 24-24 24-25
24-15 24-15 24-16 24-17 24-19 24-22 24-23
24-5.1 24-6 24-9 24-11 24-13
24-27 24-27 24-28 24-29 24-30 24-32 24-34 24-34 24-35
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28
Service
The ignition system
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28-1 28-1 28-1 28-3 28-5 28-6 28-6
Checking components and functions ....................................................................................... - Checking the hall sender (G40) ................................................................................................
Repairing the ignition system .................................................................................................... - General comments about the ignition system .......................................................................... - Safety measures ...................................................................................................................... - Removing and installing parts of the ignition system for engines with engine identification characters AXP ........................................................................................................................ - Removing and installing parts of the ignition system for engines with engine identification characters BCA ........................................................................................................................
Page
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Self-Diagnosis
General information on selfdiagnosis

Features
The engine control unit (Motronic fuel injection and ignition system control unit -J220) is equipped with a fault memory. If faults occur in the monitored sensors or components, these are stored in the fault memory with an indication of the type of fault. Faults which occur only occasionally (sporadically), are also displayed with the prefix /SP. The cause of a sporadic fault may be, for example, a loose contact or a brief open circuit in the wiring. If a sporadic fault no longer occurs within 40 warming-up phases (engine start at less than 50 C coolant temperature - engine switched off at more than 72 C), it is erased from the fault memory. The stored faults can be read with the vehicle system tester V.A.G 1552, V.A.G 1551 or VAS 5051 page 01-6. Notes: The description which follows relates only to the vehicle system tester V.A.G 1552 using the programme card 5.0 or a higher version. Use of the fault reader V.A.G 1551 with programme card version 8.0 with integrated printer, or of the vehicle system tester VAS 5051, is similar although slight differences may exist in the readouts in the display.
01
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01 Technical data for the self-diagnosis

Engine identification characters System designation Fulfils exhaust gas limit values according to Lambda regulation Knock control
Self-Diagnosis
OCTAVIA
Motronic ME 7.5 EU4
AXP, BCA
Variable intake manifold length Camshaft adjustment Secondary air system
1 knocking sensor No No
2 lambda probes
Exhaust gas recycling system
Yes
No
Selectable functions when using the vehicle system tester V.A.G 1551/1552 The conditions under which you can select the desired functions can be taken from the following table. Function on the vehicle system tester Function Engine stopped, ignition switched on Yes Engine running, idling Yes Yes Yes No Condition Vehicle running normally on the road Yes
01 Ask about the control device version 03 Actuator diagnosis
02 Interrogate the fault memory 04 Initiate the basic setting 2) 05 Delete the fault memory 06 End output 07 Code the control device 15 Readiness code
1) 2)
Yes 1) Yes Yes
Yes Yes Yes No No
Yes Yes
Yes
Yes No
Yes
Yes
08 Read the measuring block
Yes
Yes
Yes
Yes
Yes
Yes
Must be undertaken after the following work has been done: engine control unit, replacing the throttle valve control unit or the engine or unclamping of the battery
Only undertake this when the ignition is switched on, when the engine does not start (actuate the starter motor beforehand for a minimum of 6 seconds)
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Self-Diagnosis
K Installation position of EPC warning light
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01
of t for electronic panel insert (fault control) in EPC is an abbreviation for Electronic ower ontrol, which is sometimes also termed electronic throttle. After the ignition is switched on, the engine control unit checks all the components which are of importance for the operation of the EPC system. Testing operation Switch ignition on, the EPC warning light must come on. If the EPC warning light does not come on when the ignition is switched on: - Test dash panel insert Electrical System; Repair Group 90. If the EPC warning light comes on when the ignition is switched on: Start engine and run at idling speed. If the EPC warning light does not go out: Interrogate fault memory of engine control unit page 01-6.
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01
Self-Diagnosis
OCTAVIA
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 Fuses o.k. as specified in up-to-date current flow diagram. l All electrical components such as lights and rear window heater, must be switched off. l If vehicle is equipped with air conditioning, this must be switched off. l Battery voltage at least 11.5 V. l Earth connections between engine (at clutch housing) and body (below battery) o.k. Procedure KConnect the vehicle system tester V.A.G 1552.
After the vehicle system tester has been connected: Depending on the desired function, you have to: switch on ignition or start the engine page 01-2, table of Available Functions.
Notes: If no readout appears in the display, test voltage supply for diagnostic connector Fault Finding Programme in the binder Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
If the readout in the display does not correspond to the procedure: Operating instructions of vehicle system tester
Test of vehicle systems Enter address word XX
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HELP
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If Data transmission error is displayed because of an incorrect entry, disconnect cable at fault reader, plug in again and repeat the steps.
K Readout in display:
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Self-Diagnosis Note: Operate the vehicle system tester in accordance with the readout which appears on the display. Enter address word 01 for Engine electronics and confirm the entry with the key Q.
01
036906032 ME 7.5.10 Coding 00021
3257 WSC 08686
K The control unit identification and the coding appear in the display, e.g.: 036906032 = Part No. of control unit ( Parts List for current control unit version) ME 7.5.10 = System designation and version (Motronic) 3257 = Software version Coding 00021 = Coding of control unit, coding versions of engine control unit page 24-30 WSC xxxxx = Workshop code from V.A.G 1552 with which last coding was performed Notes: If the control unit version display does not match the vehicle, replace control unit page 24-29. Incorrect coding of the engine control unit results in: Poor performance (jerky gearshifts, load change jolts, etc.) Increased fuel consumption Increased emission levels
Storage of non-existent faults in the fault memory
Functions not being performed (lambda control, actuation of activated charcoal filter system, etc.) Reduction in life of automatic gearbox If the coding does not agree with the version fitted to the vehicle: Test of vehicle systems Select function XX HELP Check coding of control unit page 24-30. Press the key.
K Readout in display: Workshop Manual for further procedure.
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01
Self-Diagnosis
other.
If you have switched off the ignition between Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Note:
Only if engine does not start:
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
the
the table
starter switch
memory has to
the
and
are
the
system tester V.A.G 1552. select the with the 1
the
and aids
with the
or .
by
with the
the
to the
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it is the
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Self-Diagnosis
Test of vehicle systems Enter address word XX
HELP
K The automatic test sequence is completed once the following readout appears in the display: Erase all the fault memories and then conduct a road test.
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!
01
test When carrying out test and removal and installation work, it is possible that other control units detect faults, such as connectors unplugged. For this reason, it is necessary to interrogate and erase the fault memories of all the control units once the work is completed. To do this, you must: Press the key 0 twice for the address word Automatic test sequence and confirm the entry with the key Q. V.A.G 1552 thereupon sends all the known address words one after the other. If the control unit answers with its identification, the number of stored faults or No fault recognized appears in the display. Any faults which are stored for a system are displayed one after the other. After this, V.A.G 1552 sends the next address word. Observe the safety precautions applicable to a road test page 24-2. During this road test, the following operating conditions must be met: The coolant temperature must rise to more than 85 C. Once this temperature is reached, the following operating states must be achieved several times: Idling speed Part throttle Full throttle Enrichment Fuel shutoff on overrun Engine speed must be increased to more than 3500 rpm at full throttle. Once again interrogate the fault memories of all the control units with the Automatic test sequence. End output and switch ignition on.
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01 Fault table
Notes:
Self-Diagnosis
OCTAVIA
Explanations:
The fault table is arranged in accordance with the 5digit fault code which appears on the left.
16497 = fault code
Explanations on fault types (e.g. open circuit/short to earth): Operating instructions of vehicle system tester
Intake air temperature sender -G42 = faulty current path or fault location Signal too small = fault type as text Sporadically occurring fault = fault no longer present, e.g. loose contact
If components are shown as faulty: First of all, test the cables and plug connections to these components as well as the earth cables of the system on the basis of the current flow diagram. Replace the component only if these tests do not reveal a fault. This applies in particular if faults are displayed as occurring sporadically (SP). When testing earth cables, rectify any open circuit in wiring or short circuit according to the current flow diagram: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder.
Readout on V.A.G 1552 16490 Intake manifold pressure/air pressure G71-/-F9616491 implausible signal
When testing senders, injectors and other components of the fuel injection system, use the current flow diagrams binder.
Rectifying fault - Test sender -G71
Intake manifold pressure/air pressure G71-/-F9616492 signal too large
Intake manifold pressure/air pressure G71-/-F9616496 signal too small - Test sender -G42
Intake air temperature sender -G42 16497 signal too small
Intake air temperature sender -G42 16500 signal too large - Test sender -G62
Coolant temp. sender -G62 implausible signal
------------ 01-8 -------------
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Self-Diagnosis
01
Readout on V.A.G 1552 16501 Coolant temp. sender -G62 16502 signal too small
Rectifying fault - Test sender -G62 - Test coolant thermostat: 1.4 l/55 kW Engine - Mechanical Components; Repair Group 19
Coolant temp. sender -G62 16514 signal too large - Test lambda probe heater upstream of catalytic converter pae 24-24
Bank 1 probe 1 16515 electr. fault in circuit - Test lambda probe and lambda probe control upstream of catalytic converter page 24-24
Bank 1 probe 1 16516 voltage too small
Bank 1 probe 1 16517 voltage too large
Bank 1 probe 1 16518 signal too slow - Test lambda probe and lambda probe control upstream of catalytic converter page 24-24 - Test lambda probe heater upstream of catalytic converter page 24-24
Bank 1 probe 1 16519 no activity
Bank 1 probe 1, heating circuit electr. fault
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01
------------ 01-10 -------------
1 ) ) ' 0 0 1 ) ) ' 0 0 # & && ! ! # ! " ! $ ! $ 3'& 1& '(& % ( ( ! $ 22 &
Self-Diagnosis
OCTAVIA
on
- Test lambda probe and lambda probe control upstream of catalytic converter page 24-25 - Test lambda probe heater upstream of catalytic converter page 24-26
electr. fault in circuit 1
voltage too small 1
voltage too large 1
signal too slow 1
no activity 1
electr. fault fuel
malfunction fuel
- Test fuel pressure regulator and pressure in system page 24-19 - Test injectors page 24-17 - Test fuel pump: 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20 - Inspect intake system for leaks page 24-22 - Inspect vacuum lines for leaks
system too lean
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# 5 6 3 3 ( & # 5 6 3 3 # 5 4 6 34 3 1 2 1 3 3 0 $ % % ) $ % % ( $ % ' $ % 4 2 # # # #""""!!!! & ' 7 4 ! 4

Self-Diagnosis
01
Readout on V.A.G 1552 16556 fuel
system too rich
- Test fuel pressure regulator and pressure in system page 24-19 - Test injectors page 24-17 - Test activated charcoal filter solenoid valve page 01-29, Final control diagnosis - Test injectors
electr. fault in circuit
16603 16605 Angle
engine speed 2 TV
- Inspect engine for mechanical damage and erase fault memory page 01-6 - Test engine speed sender - Test throttle valve control unit page 24-16
16606 Angle
implausible signal 2
TV
signal too small 2
Angle
TV
signal too large
------------ 01-11 -------------
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short to positive short to earth short to positive short to earth short to positive short to earth signal too large signal too small implausible signal 1 on ------------- Test injectors - Test sender -G79
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01
Self-Diagnosis
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4 ' ' 5 " 6 1 1 2 3 4 ' ' 5 " 6 1 1 2 3 & $ $ 0 ' ' 1 1 # % # " " & $ $ 0 ' ' 1) 1 # % # 2 " & $ $ 0 ' ' 1) 1 # % # " $ $ ( ( 0 ( ( ' ' ( ( 1) 1( % " $ $ (( ( 0 ( ( ' ( ( 1)( 1( ) ( " ! !( ! !( &( 0 8# % ('( & 7 )# # )&
Self-Diagnosis
01
Readout on V.A.G 1552
- Test injectors
16655
short to earth
short to positive
Test injectors Test ignition cables and spark plugs page 28-3 Test ignition coil Test combustion misfiring
Engine
implausible signal
- Test sender -G28
Engine
no signal
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01
Indicator on the V.A.G 1552 16711 Knocking sensor 1 -G61 16712 Signal too small
Self-Diagnosis
OCTAVIA
Fault removal - Check sender -G61
Knocking sensor 1 -G61 16725 Signal too large - Check sender -G40 Page 28-5
Camshaft position sensor Sender -G40 16726 Implausible signal
Camshaft position sensor Sender -G40 16727 Signal too small
Camshaft position sensor Sender -G40 16791 Signal too large - Check the exhaust gas recycling Page 01-29 Actuator diagnosis - Check sender -G212
Potentiometer for the exhaust gas recycling -G212 16792 Signal too small
Potentiometer for the exhaust gas recycling -G212 16804 Signal too large - Replace the catalytic converter 1.4 l/55 kW engine mechanics; Rep. Size 26
Bank 1, the catalytic converter system 16806 Effect to weak
Bank 1, main catalytic converter
Effect to weak
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$ 7 7 1 6 ' 8 # 9 ! ! ! ! ! $ 7 7 1 6 ' 8 # ! 4 3 $ 2 1 5 " 0 " # ! ( % & & % ) ! ( % & & % ! ( # & & %% ! $ ! (#% 2& # ' $ " # @ 8 % 8
Self-Diagnosis
01
malfunction
- Test -N80 page 01-29, Final control diagnosis - Inspect hoses and connection pipes from fuel tank to throttle valve control unit 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20
faulty flow
- Inspect tank vent system
minor leak detected
major leak detected signal
- Test vehicle speed signal page 24-34
implausible signal
Voltage
implausible signal
- Test voltage supply to engine control unit page 24-27 - Test alternator and battery: Electrical System; Repair Group 27, Battery - Procedure in the case of voltage interruption page 24-28
Voltage
voltage too small
Voltage
voltage too large
- Test brake light switch and brake pedal switch
implausible signal unit
- Test earth cables according to current flow diagram - Replace engine control unit page 24-29
unit
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01
Self-Diagnosis
short
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Readout on V.A.G 1552 system too rich system too system too system too rich limit limit 1 2 1 est est est l/55 kW est system est system l/55 kW est EGR l/55 kW est system est est est est est est est est est est est est est est est
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Self-Diagnosis
l/55 kW system system l/55 kW
system
system
system
system
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01
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short on too too to to cat 1
------------ 01-18 -------------
01
Self-Diagnosis
of
for for
for
for
of
of
of
of
Edition 03.01 S00.5133.50.20
OCTAVIA
26
26
20
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Readout on V.A.G 1552 electr. fault in circuit electr. fault in circuit electr. fault in circuit electr. fault in circuit electr. fault electr. fault 1 1 1
OCTAVIA
Edition 03.01 S00.5133.50.20
Self-Diagnosis
------------
-------------
01
01
Readout on V.A.G 1552 17622 Injector cyl. 2 -N31 17623 short to positive
Self-Diagnosis
OCTAVIA
Rectifying fault - Test injectors
Injector cyl. 3 -N32 17624 short to positive
Injector cyl. 4 -N33 17633 short to positive - Test injectors
Injector cyl. 1 -N30 17634 short to earth
Injector cyl. 4 -N33 17645 short to earth - Test injectors
Injector cyl. 1 -N30 17646 open circuit
Injector cyl. 2 -N31 17647 open circuit
Injector cyl. 3 -N32 open circuit
------------

-------------
Edition 03.01 S00.5133.50.20
OCTAVIA
Edition 03.01 S00.5133.50.20
2 0 3 0 8 3 0 3 0 4 ( 7 4 2 3 3 0 3 0 0 65 "5 4 ) ( 0 2 5 9 3 3 0 3 5 0 6 " ) ( 4 # ' ( " ( # " 1 ( " 1 ( " " % & $ # ! " %A B" 0' A @ 5' ' 5
Self-Diagnosis
01
- Test injectors
open circuit
- Refuel vehicle
too low
control limit reached 2
- Change type of fuel - Test knock sensor - Eliminate abnormal engine running noises (loose ancillaries, bent brackets or bolt) - Test cables and plug connections according to current flow diagram - Slacken knock sensor and then tighten again to 20 Nm
control limit reached 3
control limit reached
control limit reached
- Test Hall sender -G40 page 28-4
pos.
short to earth
pos.
open/short to positive
pos. sens.
- Test sender -G28 - Test Hall sender page 28-4
incorrectly assigned
------------
-------------
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short to short to earth short to earth short to earth 1 unit gas on ------------1 1 system est est est earth est
------------
01
Self-Diagnosis
to
Edition 03.01 S00.5133.50.20
OCTAVIA
OCTAVIA
Edition 03.01 S00.5133.50.20
3 $ ! " ! 4 3 $ ! " ! 4 3 $ ! " ! 4 0 ( ' ' ) 2 3 $ ! " ! 2 ( ' ' ' " " ) 0 % & 2 1 ( ' ' ' " " ) 0 % & 1 1 ' ' ' " " ) 0 % & ' " " ) % & # " ! $ ( ( # 7 " 0 ' 5 6 6'
Self-Diagnosis
01
Readout on V.A.G 1552 gas
- Test valve -N18 page 01-29, Final control diagnosis
basic setting not performed
short to positive
short to earth
- Test valve -N80 page 01-29, Final control diagnosis - Test fuse 43
open circuit
EGR
-G212
fault in basic setting
EGR
open circuit
EGR
-G212
signal too large
EGR
-G212
signal too small
EGR
-G212
implausible signal
------------
-------------
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electr. fault in circuit signal circuit valve on ------------1) 1) 1)
------------
01
Self-Diagnosis
unit unit
unit
Edition 03.01 S00.5133.50.20
OCTAVIA
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Engine Readout on V.A.G 1552 fault in electr. fault in circuit engine fault in unit unit unit unit unit unit Electrical engine Electrical
OCTAVIA
Edition 03.01 S00.5133.50.20
Self-Diagnosis
engine
engine
engine
engine
unit
unit
unit
unit
unit
unit
unit
if
unit
unit
fault
unit
------------
-------------
01
01
------------
@ ' ' ! " ! " ( 0 0 3 A A 6 @1 '1 1 '# ( ! " ! " (1 0 0 3 ( A ( 6 2 ! 8 9 7 6 2 0 ' & ) 5 1 # 0 ! ! ! ( ( 1 ) ) & 4 3 2 # ( & ) 1 $ %# " " ! # $ %1 " " ( # # $# B0 ' # 0 ' 2 ! # ) #( ) 14 1
Self-Diagnosis
OCTAVIA
on
oltage
- Test supply voltage of engine control unit page 24-27 - Carry out procedure if interruption to supply voltage page 24-28 - Test fuse
voltage too small
oltage 1
30
voltage too small
- Replace engine control unit -J220 page 24-29
unit
Test airbag system Body Fitting Work; Repair Group 01
unit
- Test earth cables according to current flow diagram - Replace engine control unit page 24-29 - Test databus page 24-35
missing message from gearbox ECU
- Test sender -G79
signal too small
signal too large
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Edition 03.01 S00.5133.50.20
a Q 6 P A ' P 0 0 8 g y ` C Q( Q 60 6V 9t 0T 9@ A 8 A 9 U A 9 A A (U U A 9 ) ' 8 VV B ` 6U 6 6 6 D C e Q 0W )3 '3 P3 0 9 ' 8 0U 88 p% B f s% rS qT a Q6 6'b77 'f9 )T '(98 A7UVV( 9(V 06 )Q 97&@A U(0 A&U ('7 '9 0 US '0 88 (V (% T08 T8 B1 7E eU) QA 0U' )&(xe9 '76 P88 99 A@ 90 A70 0F 9 9A 0 ' q00 rP) q0(77@V y 87V&&Q 08 qVBV q76 eB ' P 8 F H 77 "8 "( 0 9(2 0X 9 A7 85 A4 P! ' 8B P1 ') 0 (8 0 ' 0 U8 UQ F T6 f 6 ) ) 8 ( 8 E D" 3 tY QV! Q(e7V&&V5 xV8 AVV76 9Ve8 AV! 9 A2 )R '0 U4 '& 0 PP$ AA&e9 '' P0) 0(` )80 9C A6 (U (87e V6 ve7(577 g)A y@ hT'@ 0B Y!( u w0 TV 7U B74 f 7((' 7( Q2 ' '4 8' 0 0e )V0 'V! p76 V s(e8" r&VV q&$ B3 f0 T) 0 ' % $ 8 @ 7" ! "V " " 1 0 ' % $ !( @ ( " " eeI 0& 9) 0 0( 8) 8 (e p7 g7A i' hV5 T0 f 2 5V&# b# dG" &# "0&7 % c97&77 "
Read fault Readout on V.A.G 1552 signal too signal too 2 2 unit signal of
OCTAVIA
Edition 03.01 S00.5133.50.20
Self-Diagnosis
to
------------
-------------
01
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Note on fault code 17978:
------------
01
The
unit
fault
fault
fault
fault
circuit
on
-------------
Self-Diagnosis
fault
unit
he
Edition 03.01 S00.5133.50.20
OCTAVIA
OCTAVIA
Self-Diagnosis
K l Fuses 7, 29, 34 and 43 must be o.k. l Battery voltage at least 11.5 V
Edition 03.01 S00.5133.50.20
1 " # 1 " ) 0 # (%! '% & # " " & # ) &$!

01 diagnosis
Notes: Final control diagnosis can only be carried out when the engine is not running and the ignition is switched on. Final control diagnosis is interrupted if the engine is started or if an engine speed pulse is registered. The control elements are checked audibly or by touching. During final control diagnosis the individual control elements continue to be operated until the test programme is switched to the next control element by pressing the key. Before repeating final control diagnosis without briefly running the engine in-between, switch the ignition off for about 20 seconds. The electric fuel pump runs during the entire final control diagnosis. Final control diagnosis is ended after 10 minutes. With final control diagnosis the following components are operated in the order stated: 1 - Solenoid valve 1 for activated charcoal filter -N80 2 - EGR valve -N18 t t and aids Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C est l All electrical components such as lights and rear window heater, must be switched off.
------------------------
01
Final control diagnosis Activated charcoal filter solenoid valve -N80
Final control diagnosis EGR valve -N18
------------
! % " 2 3 # 40 1 ' " $ # ! % ) (

Self-Diagnosis
OCTAVIA
l On vehicles fitted with air conditioning, the air conditioning must be switched off.
l There must not be any faults stored in the fault memory; rectify any faults present and erase fault memory page 01-6; Interrogating and erasing fault memory.
Connect vehicle system tester V.A.G 1552 and select address word 01 Engine electronics. The ignition must be switched on for this step. Enter function 03 Final control diagnosis and confirm entry with the key Q.
solenoid
Press
key.
The activated charcoal filter solenoid valve must be heard to continue clicking until the next control element is actuated by pressing the key.
If the solenoid valve is not actuated (does not click), test activated charcoal filter solenoid valve. of
Press
key.
EGR valve -N18 (inlet of engine compartment at cylinder head) must be heard to click.
If the solenoid valve does not click, Test EGR valve -N18. Note:
After final control diagnosis is ended, the ignition must be switched off. If the ignition is not switched off before the engine is next started, the engine will not start as the injectors and the ignition transformer are not operated.
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Edition 03.01 S00.5133.50.20
OCTAVIA
Self-Diagnosis
Readiness code 00000000 - Test complete
Readiness code 00101101 - Test not complete 0010000
Edition 03.01 S00.5133.50.20
" " 0 ) ! # ( "' " % ' " % " ' % )" & $ ' $ '
01 Readiness
The readiness code is an 8-digit numerical code which indicates the status of the diagnoses which are of relevance for exhaust emissions. If the diagnosis for a system (e.g. secondary air injection system) has been successfully completed, the corresponding place of the numerical code is set from 1 to 0. The readiness code 00000000 means that the individual diagnoses are successfully completed. The diagnoses are carried out in regular intervals during normal driving. After completing repairs to an exhaust-relevant system, it is recommended to generate the readiness code as this then ensures that these systems operate in accordance with specification. If during a diagnosis a fault is detected, this is entered in the fault memory. The readiness code is erased each time the fault memory is erased, or if the power supply is interrupted.
Reading
t
and aids
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A or 3B
Connect vehicle system tester V.A.G 1552, switch the ignition on and select the address word 01 Engine electronics page 01-4.
Enter function 15 Readiness code and confirm the entry with the key Q.
Once all the diagnoses have been successfully completed, the following readout must appear in the display:
00000000: meaning page 01-32 End output and switch ignition off.
One of the existing diagnoses was not successfully completed: Press the key.
------------
-------------
01
Self-Diagnosis -
OCTAVIA
Generate the readiness code page 01-32. Meaning of the 8-digit numerical block of the readiness code The readiness code is only generated if all the readout places are 0 1 2 3 4 5 6 7 8 0 Catalytic converter
Diagnosis function
Catalytic converter heater (no diagnosis at present/always 0) Secondary air injection system Activated charcoal filter system (fuel tank ventilation system)
Catalytic converter heating (no diagnosis at present/always 0) Lambda probe Lambda probe heater
Exhaust gas recirculation system
Generating readiness code

The readiness code must be re-generated if the fault memory of the engine control unit was erased, or if the power supply of the vehicle was interrupted. Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A or 3B Test conditions l Vehicle stationary. l On vehicles fitted with automatic gearbox, selector lever in position P or N. l All electrical components such as lights and rear window heater, must be switched off. l Coolant temperature must be at least 80 C Measured value block 004, display zone 3. l Intake air temperature less than 60 C Measured value block 004, display zone 4.
------------ 01-32 -------------
Edition 03.01 S00.5133.50.20
0 4 # $ 0 & H & # $ $ B )G 2 & 7 3 $ " @ % 7$ 4 4 % 4$ $$ ' $ % ( )6 & 3 6 $ $ I ( $ % 1 # $ 0 $ E & 3 8 # % 98 4 4 $ 4 % B $ $ % $ 0 $ 0 % A ' 1( #0 4 $4 4 $ 4 % 8 @ 88# " 0 4 4$ $ 4 $ $ 4 % % 16 0 %A R 4 4' 8 % $ 7 % & 6 3%D8 4 $ $ 0 5 $ I ( %8 B8 1' $ #$G $7 04 " # Q & ( % ) 2Q8 8 $ $ %# 7 Q $ 88P P " 5 4 #A % % %9B !64 & G C $ 88D A % 8888)55)5C'D8888Q888 88Q 99
Self-Diagnosis K K K K Step 3: Adaptation of throttle valve control unit to engine control unit If you have switched off the ignition between Interrogating fault memory and Erasing fault memory, the fault memory is not erased. Note: The readiness code is reset or cancelled each time the fault memory is erased. Note: Step 2: Erasing fault memory Step 1: Interrogating fault memory It is essential to follow the order of the steps otherwise the readiness code cannot be successfully generated. Note: Procedure in in in t in t t
------------ 01-33 -------------
OCTAVIA
Edition 03.01 S00.5133.50.20
01
01
System in basic setting 14 % 85 %
Read measured value block 111 111
System in basic setting 34 720 rpm 400.0 C 1.19
------------
# " $ !
Self-Diagnosis
OCTAVIA
60
K Check readouts in display zones 3 and 4: Display zone 3: 0...8 Display zone 4: ADP runs, ADP o.k. -
Wait at least 30 seconds before ending adaptation by pressing the key.
If the readout does not appear as described: Test throttle valve control unit page 24-16. Diagnosis of
ageing
Start engine running and run at idling speed.
Select function 08 Read measured value block and display group 030.
30
K Check operating state of lambda control upstream of catalytic converter (display zone 1): Specification: 111 -
Check operating state of lambda control downstream of catalytic converter (display zone 2): Specification: 111
Notes:
This procedure may take a few minutes.
The first place in the 3-digit numerical block changes between 0 and 1 (lambda probe heater off and on). A 0 or 1 may be displayed alternately in the 3-digit numerical block for the lambda control operating state.
Readout in display zones 1 and 2 is not set to value 1 until the catalytic converter temperature is more than 400 C ( display group 34, display zone 2). The third place in display zone 2 changes for a short time from 0 to 1 (the specification is reached as a result).
If the specification is not reached: -
Interrogate fault memory page 01-6.
If the specification is reached: -
Select function 04 Initiate basic setting and display group 034.
Test OFF
-------------
Edition 03.01 S00.5133.50.20
) A " H B ) ) # % Q & ' B ) A " 1 # ( 0 4 # % " $ $ F ) % ' ' ( & ' ' & & B " # " 0 # ) 2 # # p ) % % # % G 6 E ' `%P `!$ U d3 h i e h d c Y Y f V T T b a S g !$$P 3$ P 3 " $ ! ! R 3 @H ) !8 ! B! )!! ) # % Q & '$ )$! $$ A H B!$!!! W 1 # H Fr I5 &A'$ ' &s (( F '$ ' 9 & E U' $# s " % % u t @ "" " G!!E! ' F 'H$G!!$ 'F C) E T ) #$!$X $3 A " " # " " ! )3! $ " " % " # ! $ @ @ ) % 1 # % $ $ C B ! A " )$ "P !" " $ # $ 6 @ 9 5 4 2 H " 1 ) $$ 6 7 7# 53 8 ( 0 % % % 3 % $ $1 ' $ ! )!3 P % " 'D '$ ($! &!! ' ' & & ( $$$ 4 # $ " $ 3P $$ !$ !' $33 $!!4 !!$!!!!!$ 3$ !3!$ 3 $ $ $!!!!$!!!!P $$!$! $ !
Self-Diagnosis K This process may take a few minutes. Note: Diagnosis of l
------------------------
OCTAVIA
Edition 03.01 S00.5133.50.20
01
a " d e e " a c f e y P H P D 9 P! R B C H D P P I D E C U H P C E T V 9 9 V X & 6 3 6 & 7 1 & 0 & 1 7 0 1 ' 5 1 0 1 8 % $ 2P S " Q # I b " q c c b b " a " gP s e " b ! "& @ c c !C "! ud " t " %## s f C " !! ! a a P bU " YU eUT e " @ P b@ B T@T QT " " a V b%% "3 & %8 " " a " c % c b) %% 4 a " t a ! ! c # b# " " a " ! w v x x uq b h ! " " t a " ! f d ve p a a ! ! # b " a " " e e! f s e e s s d f ! !! c ` r ! "d ! !#! c w p " q d b h! i#d b !d a " " a " ! g f e c ` R A B! C P B A P D S A X 9 X Da D!d! CC Bd@!#d E At E H D P! E! S P W U C C P P S E H 9d# V Q @! R!b P P S!# D H## I GT Pq H E E I C I D E G D C B E A E T 9e 9 6 &F2 5F## &%#@!% 74! 0 0!y 3x 1! 1 8A 0 8V ' & %P %b $ "D !"e e @f uv F!U@d Yq@c QT !# U#Q ! x F) !!e !! ! ! !Uu e ! #( f! d TFT !! e! @g F
-------------
------------
01
Self-Diagnosis
This
Note:
Note:
is
Diagnosis of
Diagnosis of
is
Edition 03.01 S00.5133.50.20
filif
OCTAVIA
OCTAVIA
System in basic setting 70 0.0 % 0.0 %
Test of vehicle systems Select function XX
Measured value block 0 mbar 0 mbar 0 mbar
Edition 03.01 S00.5133.50.20
" # " ) # ( ( ' ( & % # $ !" 0 0

Self-Diagnosis
01
est OFF
K After the engine control diagnosis is started, the message in display zone 4 switches from Test OFF to Test ON. Continue running engine at idling speed until the specification TVV o.k. appears in the display zone.
If the message described does not appear: Interrogate fault memory page 01-6.
If the message described appears: Press key.
Diagnosis of
gas
HELP
K Readout in display: -
75 est OFF
K Readout in display: -
Drive the car a short distance (about 3...4 min).
Engine speed must reach at least 1800...3600 rpm, coolant temperature must be greater than 70 C. Take foot quickly off accelerator to produce deceleration mode. Readout in display zone 4 jumps from Test OFF to Test ON.
Braking phase must last about 8 seconds. Check readout in display zone 4. Specification: Syst. o.k.
If the message described is not displayed: Repeat braking phase several times.
If the message described again does not appear: Interrogate fault memory page 01-6.
If the message described appears: Press key.
Interrogate fault memory page 01-31.
------------
-------------
01
------------
1 % 3 % 0 9 A @ 1) 8) %) % 5 ) % 5 3 % 3 ) 5 ( # 0 9% " 2 4 3 1 5 ( # 0 % ' % # " &6 & &$ 2 7 &62 !) &

Self-Diagnosis
OCTAVIA
Pay attention to the following points if it is necessary to operate test and measuring equipment during a road test: Always attach the test and measuring equipment to the rear seat and have it operated from that point by a second person.
If the test and measuring equipment is operated from the front passenger seat, the person sitting in that seat may suffer injuries in the event of an accident in which the front passenger airbag is deployed. and aids
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C est conditions
l All electrical components such as lights and rear window heater, switched off. l If vehicles equipped with air conditioning, it must be switched off.
l There must not be any fault stored in the fault memory page 01-6. l Coolant temperature must be at least 80 C Measured value block 004, display zone 3.
Connect vehicle system tester V.A.G 1552. Start engine and select the address word 01 Engine electronics page 01-4.
Select function 08 Read measured value block and confirm the entry with the key Q. Select desired display group number from page 01-40.
Note:
Proceed as follows to switch into another display group:
-------------
Edition 03.01 S00.5133.50.20
OCTAVIA
Self-Diagnosis
Edition 03.01 S00.5133.50.20
# ( # ' & % " ! $

01
. higher lower skip Press key C Press key Press key Press key 3 Press key 1 Press key C For further procedure Repair descriptions. If the specifications for all display zones are achieved, press key. End output and switch ignition off.
------------------------
01
------------
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Self-Diagnosis
OCTAVIA
001 -
Engine idling
Read measured value block 1 xxxx rpm 1 xx.x C 2 3
xx.x %
xxxxxxxx 4
K Readout in display K Display zones
Engine speed (idling speed)
Coolant temperature
Lambda controller upstream cat
Setting conditions
80.0...110.0 C 650...850 rpm
-25.5...25.0 %
1x111111
page 01-41
page 01-44 page 01-40
of
zone 1 - Engine
(idling
on V
1552
of
less than specification
Throttle valve control unit jamming or faulty
- Test throttle valve control unit page 24-16 - Test idling speed
greater than specification
Large quantity of unmetered air (cannot be compensated by idling speed stabilisation) Throttle valve control unit jamming or faulty
- Inspect intake system for leaks page 24-22 - Interrogate fault memory
page 01-6
Large quantity of unmetered air (cannot be compensated by idling speed stabilisation)
- Inspect intake system for leaks page 24-22 - Test throttle valve control unit page 24-16 - Test idling speed
-------------
Edition 03.01 S00.5133.50.20
OCTAVIA
Self-Diagnosis
01
Analysis of indicator group 001, indicator field 4 - setting conditions 1 2 3 4 5 6 7 1 8 Meaning, when display position - 1
The engine speed is below 2000 r.p.m. The throttle valve is closed Lambda regulation in order
The coolant temperature must exceed 80 C
Idling speed established Not used
Air-conditioning unit compressor switched off
No fault recognised by the self-diagnostic function
Edition 04.02 S00.5133.51.20
------------ 01-41 -------------
01
Display group 002 - Basic functions - Air mass meter

Engine idling xxx.x % 2 x.xx ms 3
Read measured value block 2 xxxx rpm 1
Engine load
Injection time
Analysis of display group 002, display zone 3 - Injection time

Readout on V.A.G 1552 less than 2.0 ms
greater than 7.0 ms
Analysis of display group 002, display zone 4 - Intake manifold pressure

Readout on V.A.G 1552 less than 250 mbar greater than 500 mbar Possible cause of fault
------------ 01-42 -------------

Self-Diagnosis
OCTAVIA
xxx mbar 4
Intake manifold pressure
250...500 mbar 12.0...40.0 % 2.0...7.0 ms
Specification
Analysis
page 01-42
page 01-42 page 01-46 page 01-40
Possible cause of fault
Rectifying fault
High quantity of fuel out of activated charcoal filter system
- Test solenoid valve for activated charpage 01-29, Final control dicoal filter agnosis - Test quantity injected
Incorrect injectors with larger flow installed Fuel pressure too high
Increased engine load caused by electrical components, AC, gear engaged or power steering at full lock
- Test fuel pressure regulator page 24-19
- Eliminate increased load (AC, power steering etc.)
Rectifying fault
Large quantity of unmetered air between intake manifold and air mass meter Additional load from ancillaries
- Eliminate unmetered air - Test intake air pressure sender -G71
- Eliminate load (AC, power steering etc.) - Test intake air pressure sender -G71
Edition 03.01 S00.5133.50.20
OCTAVIA
Display group 003 - Basic functions - Air mass meter

Engine idling xxx mbar 2 xxx.x % 3
xx.x BTDC 4
Throttle valve angle (potentiometer 1 -G187)
Note on display zone 3:
Readout when accelerator pedal fully depressed is approx. 100 %. Display group 004 - Basic functions
Engine idling xx.xxx V 2 xxx.x C 3
xxx.x C 4
Supply voltage of engine control unit
Coolant temperature
As soon as a fault relating to the coolant temperature sender -G62 is stored in the fault memory, the engine control unit uses the intake air temperature as a substitute value for starting the engine. The temperature then rises in line with a model curve stored in the control module. After a certain time, a fixed substitute value is displayed for an engine at operating temperature. This fixed substitute value is, in turn, dependent on the intake air temperature. Note on display zone 4: The readout should be greater than the ambient temperature.
Edition 03.01 S00.5133.50.20

Self-Diagnosis
01
Ignition angle
-5.0...10.0 BZDC 250...500 mbar 0.2...5.0 %
Specification
Analysis
page 01-46 page 01-42
page 01-40
Intake air temperature
-30.0...120.0 C 80.0...110.0 C
Specification
Analysis
page 01-45 page 01-44 page 01-44
11.500...15.000 V
page 01-40
------------ 01-43 -------------
01
Self-Diagnosis
OCTAVIA
Analysis of display group 004, display zone 2 - Supply voltage of engine control unit
Readout on V.A.G 1552 less than 11.500 V Possible cause of fault Alternator faulty, battery severely discharged Rectifying fault - Test alternator and battery voltage, charge battery: Electrical System; Repair Group 27; Battery - Increase engine speed slightly for a few minutes and switch off ancillaries - Test voltage supply of engine control unit page 24-27 - Eliminate current drain - Test voltage, replace regulator if necessary - Interrogate fault memory page 01-6
Battery subjected to high loads just after start because of high charge current and ancillaries Contact resistance in power supply or in earth connection for engine control unit greater than 15.000 V Current drain although ignition off Voltage regulator at alternator faulty Excess voltage caused by jump-starting or quick-charger
Analysis of display group 004, display zone 3 - Coolant temperature

Readout on V.A.G 1552 less than 80 C Possible cause of fault Engine too cold Coolant temperature sender or cable connection to engine control unit faulty Coolant thermostat faulty Rectifying fault - Conduct road test if necessary - Test coolant temperature sender - Test coolant thermostat, replace if necessary 1.4 l/55 kW Engine - Mechanical Components; Repair Group 19 - Clean radiator - Test operation of radiator fan - Test coolant thermostat, replace if necessary 1.4 l/55 kW Engine - Mechanical Components; Repair Group 19 - Test coolant temperature sender - Test coolant temperature sender
greater than 110 C
Radiator soiled Radiator fan not operating Coolant thermostat faulty
constant -40 C constant 120 C
Open circuit in wiring or short circuit to positive Short circuit to earth
Coolant temperature sender or cable connection to engine control unit faulty
------------ 01-44 -------------
Edition 03.01 S00.5133.50.20
OCTAVIA
Self-Diagnosis
01
Analysis of display group 004, display zone 4 - Intake air temperature Note: Use only gold-plated contacts for repairing the contacts in the plug connection of the sender.
Readout on V.A.G 1552 constant -40 C constant 129 C Possible cause of fault
Short circuit to earth
Open circuit in wiring or short circuit to positive
Display group 005 - Basic functions

Engine idling xxx.x % 2 xxx km/h 3
Text 4
Engine load
Vehicle speed
Display group 006 - Basic functions

Engine idling xxx.x % 2 xxx.x C 3
xx.x % 4
Engine load
Intake air temperature
The entire temperature range is stated as a specification. The readout must be above the ambient temperature.
Edition 03.01 S00.5133.50.20

Rectifying fault - Test intake air temperature sender -G42 K Readout in display K Display zones Operating state (idling, part load, full load, enrichment, overrun) Specification Idling Analysis 12.0...40.0 % 0 km/h page 01-46 page 01-40 K Readout in display K Display zones Altitude correction factor -30.0...120.0 C 12.0...40.0 % -50.0...20.0 % Specification Analysis page 01-45 page 01-46 page 01-40 ------------ 01-45 -------------
01
Reading measured value blocks, display groups 010...029

Display group 010 - Ignition
Engine idling
Read measured value block 10 xxxx rpm 1 xxx.x % 2 3
Readout when accelerator pedal fully depressed is approx. 100 %. Analysis of display group 010, display zone 2 - Engine load
Readout on V.A.G 1552 less than 12.0 %
Analysis of display group 010, display zone 3 - Throttle valve angle, potentiometer 1
Readout on V.A.G 1552 greater than 5 % Possible cause of fault
------------

Self-Diagnosis
OCTAVIA
xxx.x %
xx.x BTDC 4
Engine load
Ignition angle
-5.0...10.0 BTDC 12.0...40.0 % 0.2...5.0 %
Specification
Analysis
page 01-46 page 01-46 page 01-40
Rectifying fault
greater than 40.0 %
Smaller readouts occur only in fuel shutoff on overrun
Poor idling (not running on all cylinders) Electrical components on
- Test injectors - Replace spark plugs if necessary - Switch off electrical components
Steering wheel at full lock
- Turn steering wheel into straightahead position - Test throttle valve control unit page 24-16
Throttle valve control unit faulty
Rectifying fault
Engine control unit not adapted to throttle valve control unit Throttle valve potentiometer in throttle valve control unit faulty Throttle valve jamming
- Adapt engine control unit to throttle valve control unit page 24-32 page 01-6 - Interrogate fault memory
- Test throttle valve control unit page 24-16 - Eliminate cause
-------------
Edition 03.01 S00.5133.50.20
OCTAVIA
) A 86 B B 5 8 7 5 0 2 2 1 9 3 @ G a $ Q V T P4 A& P `3% 53B 83B 26c 147 6 49 H1 @cU H I @ G $ S % % D F )&! A4P 85 7E 51 07 21 2 12 86" B@Pc B 56dU 933B3 34W @3X 3b 35 " 5 ' R & & 6 ! ! ! #R % $
Self-Diagnosis
01
Driving
Read measured value block 14 xxxx rpm 1 xxx.x % 2 xxx 3
Text 4
Engine load
Total of ignition misfirings
Misfiring detection status (activated, deactivated)
activated 0
650...5700 rpm
12.0...100.0 %
page 01-47
of
3 - otal of ignition
of
on
greater than 0
Spark plug faulty Ignition cable termination faulty Ignition coil faulty Power output stages for ignition coil faulty Injector faulty
- Test spark plugs and ignition cable with termination - Test ignition coil - Test injectors
Driving
Read measured value block 15 xxx 1 xxx 2 xxx 3
Text 4
Ignition misfiring cylinder 1
activated 0
page 01-48 page 01-48
page 01-48
Edition 03.01 S00.5133.50.20
------------
-------------
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01
Self-Diagnosis
OCTAVIA
on
of
greater
plug faulty cable termination faulty coil faulty output stages for ignition coil faulty faulty
est spark plugs and ignition cable termination est ignition coil est
Driving
Read measured value block xxx 1
ext
K Readout in display
Display zones
activated
misfiring cylinder
page
------------
-------------
Edition 03.01 S00.5133.50.20
OCTAVIA
Note on display zones of
5 6 S d j 0 X 4 5 6 j j k l ( 2 0 5 4 6 g 7 4 7 d d 6 4 6 S 5 ( 5 6 S d $ 7 f % 5 6 S 5 6 e d7 uUTs P D G A UT @ I5 E sXI f4 4 H r6 b ` $V XX 4 4 YThTiS 2S (X 0 %4 )4 % 0 %5 %5 $( X U XX 5 4 5 S Y'V5 2VXgcUT (6U 0V %u4 )Vf %ES 0# % % $T XVX VX4 5 S YT 2'VQ (VT 0V6X %V )$t %X 0 % % $T V@ V2U XCVUT 6e 5T U YUBV# 2'VA (V55 05 %pB )6f %C 04$ %S %hU 'VF R PIB5u 6pS 5 4F 7U5 GEV Q5 Qh DCx GDpU FV3 D# 9@ A@ AiTD @QR ES$ HT 80 BUuv I1) CQ% BVD0 Bqy B 2 1 (T' )V ( ) ( ) ( ' ) ' $ T'U %E aTT' !aR !U #0 RUT "a w Tw
Self-Diagnosis
01
ignition -
Driving
Read measured value block xx.x xx.x
xx.x
xx.x
K Readout in display K Display
angle retardation in cylinder
control
angle retardation in cylinder by knock control by knock
page
page
by knock control
by knock control
page
page
The readout in the idling speed range is 0.0 CA.
angle
on
of
all cylinders greater
sensor
est knock sensor
connection corroded
sensor not correctly
Engine components loose connection corroded
to
knock sensor and
again
loose components type
one cylinder
est knock sensor est
ers
Engine damaged
Engine components loose
Engine ponents; Repair Group
loose components
Edition 03.01 S00.5133.50.20
------------
-------------
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Read measured value block Read measured value block
------------
01
Note on display zones 3 and
Note on display zones 3 and
Driving
Driving
-------------
load
load
angle
angle
angle knock
angle knock
Self-Diagnosis
in
in
knock
knock
Edition 03.01 S00.5133.50.20
OCTAVIA
OCTAVIA
Analysis of display groups

Readout on V.A.G
all cylinders greater than 12.0 CA
one cylinder differs significantly from the others
Display group

Driving Control unit in function 04 Initiate basic setting 4 xxx.x % 2 xxx.x C 3 Text
System in basic setting 28 xxxx rpm 1
Engine speed
Edition 03.01 S00.5133.50.20
B 6% # 0 C ) ) ( 3 4 % % @ A 1%1 59 7( 6" 0& )0 () 3%# 3 2$ 4( '$ 4$ 8 ! % '

Self-Diagnosis 3 and -
01
display
angle retardation
of fault
Knock sensor faulty
- Test knock sensor
Plug connection corroded
Knock sensor incorrectly tightened Engine components loose Poor quality fuel Plug connection corroded Engine damage
- Slacken knock sensor and tighten again to 20 Nm - Tighten loose components - Change grade of fuel - Test knock sensor
Engine components loose
- Tighten loose components
- Test compression: 1.4 l/55 kW Engin - Mechanical Components; Repair Group 15
ignition -
sensor
Engine load
Coolant temperature
Result of knock sensor test (Test ON/Test OFF/Syst. o.k./Syst. n.o.k.)
K Display zones
Syst. o.k.
Analysis
40.0...110.0 C 15.0...100.0 %
page 01-44
2200...5700 rpm
------------
-------------
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Read measured value block
------------
01
Notes:
Display group 030 -
Reading measured value blocks, display groups
400 C (
A0
The
xxx
Engine idling
-------------
xxx
lambda control upstream
probe operational
control active
probe
o lambda control catalytic converter converter temperature at least group display
control
on
2).
catalytic converter
Self-Diagnosis
01
099 -
Specification
control
Edition 03.01 S00.5133.50.20 Analysis page page
OCTAVIA
OCTAVIA
Notes on display zones 1 and 2:
g qi 3i 2i h h h 2 h h 2 g i i gb X d X q7 3ic 2e5Y hg h h 2 h h 2 Via V9 V95 Vc 4 ) D C B 6 Ti` Si9 Q98 Fe H7 H` G@0 RD UD` E6 PA IiX Iff I3 ) 0 & 2 5a 9 '8W $5 c59 ( 'Y W '% $ 5 # "` " ! " ! 89
Self-Diagnosis
01
Engine idling
Read measured value block xx.x % xx.x %
nalysis
learned value at idling speed
learned value at part load
page
page
Low values indicate that the engine is running too rich and for this reason the lambda control produces a leaner mixture. High values mean that the engine is running too lean and the lambda control therefore produces a richer mixture. All the learned values are reset if the control unit is de-energized.
add = additive - The fault (e.g. unmetered air) always has a far less pronounced effect as engine speed rises. In the case of the additive learned value the injection time is altered by a fixed amount. The amount is not dependent on the basic injection time. mul = multiplicative - The fault (e.g. faulty injector) has an increasingly pronounced effect as engine speed rises. In the case of the multiplicative learned value this is a percentage change in the injection time. This change is dependent on the basic injection time. Learning conditions for idling speed. Coolant temperature at least 80 C, intake air temperature max. 90 C.
Learning conditions for part load. Coolant temperature at least 80 C, intake air temperature max. 90 C.
Edition 03.01 S00.5133.50.20
------------
-------------
01
------------
H32 H8 H 3DCD IE 3 Q)F PB 00( G01 )G 4D) 4C FC (2) F 5 %9 6 4 #4A6 ! ' #0 " !@ &@ $ 3 7
Self-Diagnosis -
OCTAVIA
of d
1 and
learned
on
of
low lambda learned values
Low lambda idling learned values with normal lambda part throttle learned values: oil dilution (high level of fuel in oil) possible Injector leaking
- Disappears after driving on motorway or changing oil
- Test injectors
Fuel pressure too high
- Test fuel pressure regulator and holding pressure page 24-19
Solenoid valve for activated charcoal filter constantly open Lambda probe heater faulty or lambda probe dirty
- Test solenoid valve for activated charcoal filter page 01-29, Final control diagnosis
- Test lambda probe heater
high lambda learned values
High lambda idling learned values with less high lambda part throttle learned values: unmetered air possible in intake manifold area Injector leaking
- Inspect intake system for leaks page 24-22
- Test injected quantity
Fuel pressure too low
- Test fuel pressure regulator and holding pressure page 24-19 - Rectify cause
Unmetered air at the manifold gasket
Lambda probe heater faulty or lambda probe dirty
- Test lambda probe heater
-------------
Edition 03.01 S00.5133.50.20
y y h y y fy d e e d B@ B3 eg 1 s 0 i 0 vs v CB1 w F1 w F B1 Bii B B e08 p p4 @3 g 3 0 7 1 3 i 0 3h 1 s g s 3 8 1 5 5r 5 DBs tp E Gg E8 6j f e e e1 e H9 ' Ih @ cu4E 0 P 3 7 1 7 `1 dy dh W `Bs5 Y0i W0 Ri TPi T0 Sy Xq aP2 Q U0 bd5 V166 UB59 U81 U3rg Gg F 9 A C D )A ' ' 4 @ 3 1f 05 193 852 7P 2 2s 69i $ A i 75g %5h "5 &B %B % A " 99 ! A # A A i
Edition 03.01 S00.5133.50.20 Read measured value block
OCTAVIA
The readout to
Engine idling
there
Self-Diagnosis
in
the
the
------------
-------------
01
01
The period indicates the time between two voltage jumps (e.g. rich - lean - rich) of the lambda probe and is thus a measure for the state of ageing of the lambda probe. If the specified period is exceeded, B1-S1 n.o.k. appears in the display zone 4. -
Note on display zones 3 and 4:
------------
1 C5 @8 D5 D5 7 @ 9 7 2 4 4 3 A6 5 B G $F ($ ( ) H # # $ ( % " 1% C! @## D% D" 7" @ 9$ 7% 2 4 4 3 A(% 58 B6 5( ( $& (5" ( ) # #$ %! %% # %$ # (' %5 ! " ! '
Self-Diagnosis
OCTAVIA
Control unit in function 04 Initiate basic setting Brake pedal operated Vehicle stationary, engine running at fast idling speed xxx.x C 2 x.xx 3 Text 4
Engine speed
Catalytic converter temperature
Period of lambda probe upstream of catalytic converter
Result of ageing test of lambda probe upstream of catalytic converter (test OFF/test ON/B1-S1 o.k./B1-S1 n.o.k.)
B1-S1 ok
0.7...2.00
at least 400.0 C 1100...1400 rpm
Value calculated from engine speed and engine load.
of
Engine idling
Read measured value block 36 x.xxx V 1 xxx.x C 2 x.xx 3
Text 4
Lambda probe voltage downstream of catalytic converter
Catalytic converter temperature
Specification lambda probe downstream of catalytic converter
Test lambda probe downstream of catalytic converter (Test OFF/Test ON/B1-S2 ok/B1-S2 nok)
B1-S2 ok
at least 400,0 C 0.000...1.000 V
page 01-57
-------------
Edition 03.01 S00.5133.50.20
OCTAVIA
Analysis of display group

Display zone: 1 constant 1.085 V
$ '# ! (" " '' % " & " " ) ! %
Self-Diagnosis
01
A voltage jump from 0.700...0.900 V to 0.000...0.300 V and vice versa takes place at transition from rich to lean and vice versa ( = 1.0). In view of the steep voltage jump, the lambda control is not able to maintain constant the ideal mixture composition which corresponds to = 1.0. The control constantly fluctuates back and forward between the slightly too lean and slightly too rich states. Control value difference between rich and lean mixture is approx. 0.630 V.
The voltage signal lean mixture (large level of residual oxygen) is at approx. 0.000...0.300 V.
The voltage signal rich mixture (low level of residual oxygen) is at approx. 0.700...0.900 V.
K Voltage of 4-pin lambda probe U in mV A: Lambda probe voltage high high CO level
rich mixture (fuel excess or air deficiency) B: Lambda probe voltage low low CO level
lean mixture (fuel deficiency or air excess)
display zone 1 -
of
Rectifying fault
constant 0.400...0.500 V
Short circuit to positive caused by: Lambda probe Lambda probe cable Earth cable Engine control unit Open circuit in wiring caused by: Lambda probe Lambda probe cable Earth cable Engine control unit Short circuit to earth caused by: Lambda probe Lambda probe cable Earth cable Engine control unit
- Test lambda probe voltage downstream of catalytic converter page 24-25 - Test lambda probe cable downstream of page 24-25 catalytic converter
constant 0.000 V
Edition 03.01 S00.5133.50.20
------------
-------------
01
Display group 037, lambda control - Readiness downstream of catalytic converter

Engine idling Control unit in function 04 Initiate basic setting xxx % 1 x.xxx V 2 xxx.xxx 3 Text 4
System in basic setting 37
Engine load
Lambda probe voltage downstream of catalytic converter
Ignore
Display group 041, lambda control - Lambda probe heater

Engine idling Text 2 -
Read measured value block 41 1 3
Text 4
Lambda probe heater upstream of catalytic converter
Note:
Depending on operating state of the engine, the lambda probe heaters are switched on or off, in other words the readouts in display zones 2 and 4 may either be Htg.b.(a.)C.ON or alternately Htg.b.(a.)C.ON/Htg.b.(a.)C.OFF.
------------ 01-58 -------------

Self-Diagnosis
OCTAVIA
Test lambda probe (Test ON/Test OFF, Syst. ok/Syst. nok)
Specification Syst. ok
Analysis
0.000...1.000 V 12.0...40.0 %
page 01-57 page 01-46
Lambda probe heater downstream of catalytic converter
Htg. a.C. OFF Htg. a.C. ON
Specification
Analysis
Htg. b.C. OFF Htg. b.C. ON
Edition 03.01 S00.5133.50.20
OCTAVIA
Display group 046, lambda control - Diagnosis of catalytic converter

Control unit in function 04 Initiate basic setting Brake pedal operated Vehicle stationary, engine running at fast idling speed xxxx C 2 x.xx 3 Text 4
Display group 099, lambda control - Operating state of lambda control

Engine idling Control unit in function 04 - Initiate basic setting, lambda control off Control unit in function 08 - Read measured value block, lambda control on xxx.x C 2 xx.x % 3 Text 4 K Readout in display K Display zones
Note on display group 099:

Self-Diagnosis
System in basic setting 46 xxxx rpm 1 K Readout in display K Display zones Engine speed Catalytic converter temperature Amplitude ratio Result of catalyst ageing test (Test OFF/Test ON/Cat B1 ok/Cat B1 nok) Specification Cat B1 ok Analysis 1100...1400 rpm min. 400.0 C 0.00...0.50 Read measured value block 99 xxxx rpm 1 Engine speed (idling speed) Coolant temperature Lambda controller upstream of catalytic converter Operating state of lambda control of lambda probe upstream of catalytic converter Specification ctrl. OFF or ctrl. ON Analysis -25.0...25.0 % 80...110 C page 01-44 page 01-40
01
For defined fault finding, the lambda control is switched off when display group 099 is selected under Initiate basic setting, or is switched on when selected under Read measured value block. The lambda control is automatically active again when function 04 Basic setting is quit.
Edition 03.01 S00.5133.50.20
------------ 01-59 -------------
01
Reading measured value blocks, display groups

Display group
Note on display zone 2: Note on display zone 3:
What is displayed is the specified engine speed set by the engine control unit (value computed in control unit). A/C High = air conditioning demands high heating or cooling capacity A/C Low = air conditioning not switched on Notes on display zone 4:
------------
R h e ' $ e R ! d e G Yb ) H X RSc G FE1 V1 W1 Hb @ P1 I1 AF )1 @F Hb Tb T1 T T RB) PA IA A0 )C 0 B @A QS2 H1 H 3G ( 7@ 4QE 8@ 8H 5BC 1U 0S ) 2 ' & 9GD 6@ # ! % D c ` UEE $ # 2 F EB AEfE a` A 0 2
Self-Diagnosis
OCTAVIA
engine speed limiting -
states
Engine idling
Read measured value block xxxx rpm xxxx rpm
ext
ext
K Readout in display K Display
state
compressor
Specification or
state
or
Engine speed
Engine speed
idling
rpm
page
On models not fitted with air conditioning Compr. OFF is always displayed. Test signal from and to AC compressor.
If accelerator pedal is depressed suddenly, the readout in display zone 4 must jump from on to off for a few seconds (AC compressor switched off when vehicle accelerates).
-------------
Edition 03.01 S00.5133.50.20
i g k V H E G! &h # G V! "! G G # G G # ! ! Vi " G G S ! ! "! G U G U S HH ! EH H $!f I # G! B5e 97E CT CT 6 9! 8! 6 1 3) 3 2 ) @ 0 4 A4! 4) 4) " " e c b u xh x x x b w b g v y aw d ( ! !d H'e )d Ej !kl Gi &k #ja Gg Gh Ug G I ) d VE Vk& ) R E ) c !!c !i !D VE )r Q ) p r R R ) ) "! g G G G # G G # H Q % ` U # # Y) ! ! !y V) E P E "!Y G Gy G # G G 'X BD ( q 9e) Cv C 6 9! 8RQ 6! 1 3 3 2 ) g 7d @R 0HX 4a A) 5Q# 4w# 4a 4)W & % ! "b " a $ ! e Y a $ Q &h f gad wc u!a ca e xc cX xb x!d bv gd wt hXv c p i g f e vt r d yYh a ` s q a a a
Edition 03.01 S00.5133.50.20 Driving Read measured value block Read measured value block Engine idling Engine Engine
The readout or a the
OCTAVIA
engine
engine
n the
value
range
on
idling
Self-Diagnosis
valve angle
in
in
states
the
and
the
------------
-------------
01
01
What is displayed is the specified engine speed
------------
e XY Y X U i W Y g W Y g c f aa X Y c U X `X V h b T 7b IDa FA` ES C 8 @ @ 9 FbbR PU PÀ`TU C`W GBS Ad HV A "2pT q ` ("c )T" ( ( ) ! ( #Y %) ' 50 3 & 1 ) " ! 4 ! # $( " "
Self-Diagnosis
OCTAVIA
4 x
AC compressor switched on Ignore
Meaning
AC switched on Ignore Ignore
engine
Engine idling
Read measured value block 56 xxxx rpm 1 xxxx rpm 2 3
xx.x %
xxxxx 4
Engine speed (specified idling speed)
Idling speed controller
Operating states
-10.0...10.0 % 750 rpm
xxxxx
page 01-62
page 01-40
is set
the engine
-------------
Edition 03.01 S00.5133.50.20
OCTAVIA
Display group 060, engine speed control - Adapting electronic throttle system1)
Ignition on, engine not running Control unit in function 04 Initiate basic setting xx % 2 x Text 4
Notes on display group 060:
Display group 061, engine speed control - Electronic throttle system

Driving

Self-Diagnosis
01
System in basic setting 60 xx % 1
Learning steps counter
Adaptation state (ADP runs, ADP o.k. or ADP ERROR)
Specification ADP. o.k. 0...8
Analysis
10...90 %
90...10 %
1)
Adapting engine control unit to throttle valve control unit
page 24-32.
Adaptation of the throttle valve control unit is performed with the ignition switched on.
If display group 060 is selected in function 04 Initiate basic setting, the engine control unit is adapted to the throttle valve control unit. This adaptation must always be performed if another throttle valve control unit (or complete different engine) or another engine control unit has been installed. If the voltage supply was interrupted (battery disconnected), it is also necessary to carry out adaptation page 24-28, Procedure after interruption of voltage supply.
Read measured value block 61 xxxx rpm 1 2 3
xxx.x %
xxxxx 4
Operating states
Specification 0.0...100.0 % xxxxx
Analysis
page 01-62
Engine speed
650...5700 rpm
Edition 03.01 S00.5133.50.20
------------ 01-63 -------------
01
Self-Diagnosis
OCTAVIA
Display group 062, engine speed control - Electronic throttle system Notes: The reason why the readout in display zone 1 rises as a percentage and the readout in display zone 2, in contrast, drops, is because of the contra-synchronism of the potentiometers (angle sensors) in the throttle valve control unit.
The readout displayed in display zone 3 must always be approximately twice as much as the readout in display zone 4.
Ignition on, engine not running
The engine control unit converts the voltage values of the accelerator pedal sensors into a percentage (related to 5 V). Supply voltage of 5 V equals 100 %.
The voltage tap of angle sensor 2 moves away from 5 V in the direction of 0 V. (The more the throttle valve is open, the less is the voltage; the percentage readout drops).
This means that the voltage tap of the one angle sensor moves in the direction of 5 V. (The more the throttle valve is open, the greater is the voltage; the percentage readout rises).
------------
6 6 86 '3 I$ 7 IH ( @ 6 6 6 8A F 3 '3 I (( I 7$ @ A ( H 6A 6( 6 83 9 D $ $ 3 C "#F C ' @ 7C (4 ( 7 3 $ B @ A ( 6 6 6 8 " $# 9 9 ' 7 0 4 03 9 5 1G 2G % ( 3D " "" $E 0 ) &" &" & & & & ' ' ' ' #& %3 " " $" " ## 5"& ""## " E #
K in K Specification Analysis ------------Edition 03.01 S00.5133.50.20
OCTAVIA
Display group 066 - Brake and clutch pedal switch

Engine idling
Meaning of the digits in the 4-digit readout, display zone 2, switch for brake, clutch and CCS 1 1 1 1 Meaning

Self-Diagnosis
01
Read measured value block 66 km/h 1 xxxx 2 km/h 3
xxxx 4
Vehicle speed (actual)
Switch position of brake, clutch and CCS
Specified vehicle speed (speed last stored by CCS)
CCS switch position1)
Specification 0000
Analysis
0 km/h
0000
page 01-65
Brake depressed (brake light switch) Clutch depressed CCS activated1)
Brake depressed (brake pedal switch)
1)
Test clutch pedal switch.
Not available at present
Test brake pedal and brake pedal switch.
Edition 03.01 S00.5133.50.20
------------ 01-65 -------------
01
Reading measured value blocks, display groups 070...079
Display group 070, exhaust reduction - Diagnosis of activated charcoal filter system
Engine idling in
Note:
TVV means tank vent valve (solenoid valve for activated charcoal filter system). Diagnosis can only be initiated once for each engine start. Note on display zone 2: The readout must not be greater than 5 % during the diagnosis.
Display group 074, exhaust gas recirculation

in
Note:
Adaptation must always be performed if another EGR valve or engine control unit is installed.
------------ 01-66 -------------
C 6 4 6 C T Q 5 C1 H T 6 70000000 D0000 7 8 $ 3 C ' ( " 000( H H 1" 0" Q000 Q$H 00 0 () " " 10 C C4 3 (! () ) C C6 @ C CG 3 D4 E E D F ' ( C " P " I S ) 3 C3 C0B @# A" D 3! 3 BF 9)5 7 $% 8 ! ) ( ! 69 ( 4 ) ) 1 3 1 ' % $ ) C P " () ( # "5 H ! 0) ) ) 2) ) ) ! $ ) 0000 ) $ ) )
Self-Diagnosis
OCTAVIA
in
in
Specification
Analysis
<5
in
in
Specification A P
Analysis
Edition 03.01 S00.5133.50.20
OCTAVIA
Display group
Driving
Display group 100 Engine idling
# 2' 1 ) $ & & % 0 ( ' ' D B 4 5 4 A 5 4 9 8 6 3 6 #G 2'@ 1R )Q $F &I & %H 0B (! ' 'R !P4 C7 E E 5
Self-Diagnosis
01
gas
diagnosis
Read measured value block 75 xxx mbar 1 xxx mbar 2 3
xxx mbar
Text 4
Rapid compensation jump during diagnosis
Intake manifold pressure difference
Result of test: Test ON/Test OFF/Syst. ok/Syst. nok
Syst. ok
Analysis
display group 100
Read measured value block 100 xxxxxxxx 1 xxx.x C 2 xxx.x s 3
xxxxxxxx 4
Readiness code
Coolant temperature
Time since engine start
Diagnosis status
80.0...110.0 C 00000000
Analysis
page 01-44
page 01-68
Edition 03.01 S00.5133.50.20
------------
-------------
01
------------
# $ " " ! !
Self-Diagnosis
OCTAVIA
of -digit
display
The readiness code is generated only if all readouts are 0 1 2 3 4 5 6 7 8 0 Diagnosis function Catalytic converter
Catalytic converter heater (no diagnosis at present/always 0) Activated charcoal filter system (tank vent system)
Air conditioning (no diagnosis at present/always 0) Lambda probes Lambda probe heater
Secondary air system (no diagnosis at present/always 0)
Exhaust gas recirculation
-------------
Edition 03.01 S00.5133.50.20
OCTAVIA
Fuel Formation/Fuel Injection
Servicing fuel injection system

General information
General information on ignition system page 28-1, Servicing ignition system. The engine control unit is equipped with selfdiagnosis. The first step before commencing repairs and also fault finding, is to interrogate the fault memory. Likewise, also inspect the vacuum hoses and connections (for unmetered air). Fuel hoses in the engine compartment must be secured only using spring strap clamps. The use of collar clamps or screw-type clamps is not permitted.
24
Always switch off the ignition before disconnecting and re-connecting the battery otherwise the engine control unit may be damaged. Components marked with * are tested by selfdiagnosis page 01-6, Interrogating and erasing fault memory.
Components marked with ** can be tested with the final control diagnosis page 01-29. A voltage of at least 11.5 V is required for proper operation of the electrical components. Do not use any sealants containing silicone. Traces of silicone elements inducted by the engine, are not combusted in the engine and damage the lambda probe.
When conducting certain tests it is possible that a fault is detected by the control unit and is stored. For this reason, after completing all the tests and repair work, interrogate the fault memory and erase it, if necessary page 01-6, Interrogating and erasing fault memory. Safety precautions page 24-2. Rules for cleanliness page 24-3. Technical data page 24-3. Testing operating states of the engine page 01-45, display group 005.
Edition 03.01 S00.5133.50.20
------------ 24-1 -------------
24
OCTAVIA
Safety measures
Note! The fuel system is pressurised! Place cleaning cloths around the connections before loosening hose connections or opening test connections. Then let the pressure out carefully by pulling off slowly. The following points should be observed in order to avoid injury to persons and/or destruction of the injection and ignition system: Do not touch or remove ignition leads while the engine is running or at start speed. Only remove or attach lines to the injection and ignition system and also the measuring device lines when the ignition is switched off. Please observe the following if it becomes necessary to use checking and testing equipment when undertaking a test drive: The checking and testing equipment are always to be fixed to the rear seat and also to be operated from there by a second person. If the checking and testing equipment were also operated from the front passenger seat then the person there could suffer injury from the airbag if a crash occurred. When the engine should be run at the starter speed without firing: For engines with engine identification characters AXP Kpull out the 4-pin connecting plug from the ignition transformer -arrow-
For engines with engine identification characters BCA
------------

K-------------
pull out all ignition coils using extractor T10094.
For all engines pull out the connecting plug on the injection valve -arrows-
Edition 04.02 S00.5133.51.20
OCTAVIA
Edition 03.01 S00.5133.50.20

24
Pay careful attention to the following 5 rules for cleanliness when carrying out work on the fuel supply and injection system: Thoroughly clean connection points and the surrounding area before disconnecting. Place removed parts down onto 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.
------------------------
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4 3 2 Nominal resistance Page 24-14
-------------
24
------------
intake t
or t
Page 28-3, position 6
(Motronic control unit - J220) Below the plenum chamber cover
connection
control unit (J338)
Edition 04.02 S00.5133.51.20
OCTAVIA
OCTAVIA
lug connection 10 3 grey, for engine speed sender (G28) 11
12 6 lug connection black for lambda probe and lambda probe heater 13
Edition 03.01 S00.5133.50.20
! 1 # ! 1 1 3 " 5 24 3 & ! 2 1 0 # "' $ % ) ( !4 )& "% " (

Fuel Formation/Fuel Injection 14
24
Engine fitting location: at inlet side of cylinder block page 24-7, item 14
valve
with
15 Hall page 28-3, item 9
16 Lambda converter
with marking for ignition cables, do not mix up page 28-3, item 2
of catalytic 50 Nm, lambda of catalytic converter
fitting location: lambda probe upstream of catalyst, in exhaust manifold; lambda probe downstream of catalyst, behind main catalytic converter
17 Activated charcoal filter
valve
with coolant temperature gauge sender (G2) testing page 24-14
activated charcoal filter: 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20
------------ 24-5 -------------
4 F s t 9 ' T 4 0 T ' 9 f` f' YG U VtY YT XD 4 T hV dW F `' h Y Y W V W Y 5 gt g 7 `' Vc V3 h` `0 S s a$4 q r d Q @ 75` &(YX 05B 74 0$h 7C 3R rAV 79 'bP 2$8 0 ' 7 2 4 ' 2 4 57 ' E G $D '5 ' C ' 2 & ' F 9 9 # AH ) @ @ $e 'aA& 7aE TC 0w4 40 T$r 7Y rT '7 B2 7 2 0 ' 7 ' ' sA2') s(1 x5'A) x(5v9 y2') xb74 Gf D3 9 6 8 ) ( @IW2 $45$ 08# 7(85) 4dAa5 7i25 ''5((( 4'WW 1d 0G &$ 3$ 4a 0 ' & ' 2(5 uHGD 8572 HpC )5h2( (Wd2bA A75bD vgeAA$ % ! "
4 3 2 Nominal resistance Page 24-14
-------------
24
------------
intake t
or t
connection
control
control unit (J338)
Edition 04.02 S00.5133.51.20
OCTAVIA
OCTAVIA
10 - Knocking sensor 1 (G61) page 28-5 Position 4
Fuel preparation/injection 15 - Valve for the exhaust gas recycling (N18) with a potentiometer for exhaust gas recycling (G212) 16 - Hall sender (G40) page 28-5 Position 7 17 - Lambda probe before the catalytic converter (G39), 50 Nm, lambda probe after the catalytic converter (G130), 50 Nm Installed location: lambda probe before the catalytic converter in exhaust manifold, lambda probe after the catalytic converter behind the main catalytic converter 18 - Solenoid valve for the activated charcoal container (N80) activated charcoal container: 1.4/55 kW engine - mechanics; Rep. Gr. 20 19 - Ignition coils with power transformer (N70, N127, N291 and N292)
24
11 - Sender for the engine speed (G28) installed location: the cylinder block on the suction side page 24-7 Position 14 12 - 3-pin plug connector grey for the sender for the engine speed (G28) 13 - 6-pin plug connector black for the lambda probe and lambda probe heating 14 - Sender for the coolant temperature (G62) with coolant temperature indicator (G2) checking page 24-14
Edition 04.02 S00.5133.51.20
------------

-------------
24
OCTAVIA
Removing and installing parts of fuel injection system
1 - Plug
2 - 3 Nm
3 - Air filter disassembling and assembling page 24-13 4 - Cable duct clipped onto fuel rail
------------

-------------
5 - 10 Nm 6 - Fuel rail with injectors disassembling and assembling bottom part of intake manifold page 24-9
7 - Intake manifold disassembling and assembling page 24-9
Edition 03.01 S00.5133.50.20
OCTAVIA
24
activated charcoal filter system 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20 connection black for throttle valve control unit (J338) contacts gold-plated
10 F
Edition 03.01 S00.5133.50.20
& ( 2) 6 5 # )% 4 !$ & &( ' 0 & 1 3 & ! " ' # 2 1
From 11 replace 12 to EGR valve 13 14 testing page 01-40
------------------------
3 3 3 3 3 3 @ @ A 7 6 8 Q D A H 6 6 H F F 3 3 3 h @ AH A 6 7 Q 8 8 D A 6 6 A H D F F t 6 i P t # # # u r 3 D A 8 D A 8 i D S W q W t g 6 i P t # # # u y # # $ # v u S q q V 3BH 3 3 3 b 3 3 3 D @ Ad 8I D 7 6 Q Ht Ft 6 i P # # # u ' S 3 3 3 3 A7 Qt 8i 8 H S D H V P F7 Fp g9 d 6 i P t #D D #Q #8 D 3 A A uQ ' 3 i 3 D 87 A8 DH iA H D i Cc i YC 3 Y9 TH Y 3 3 6# i6 H D P# P 3 #EBA 8 b #b #D D s d c A u# y98 3 V F 3# Q8 76 D3 63 QG AD AD D SC3 # T98 V 5 3EBHA htBQ @6 Dtc Q3 D8h8 6g Ai 6Q i A iH UG UD 3 E7 c 5A tD p) W BD % 3H 3b @3 A"3 6" 75 Ac Qc 7 Q 7D DD tE903 C3 3 3 6 6 6Q QA GQ 6 Q i F 3u 3A @@ QHHc 6HAi ICc 8H3 Q 6@ iI c7H A QT 8"c 8u 7u iD s # 5F 3EcBCE 7A PiH 3 3 399B #0Q A 5E #A D A G 3 c G 7 A 5 s # # w 3DHE 3DE Qq 77 DCW 63 Q3 S8 F T9C6 V3 36 hg"3H 6g3 A@ 6B@ id@ i@ @& DAI QH"d3 DE0B9 # U3 U3 0 B3 E@ 5@ p3 u v 33 3C8 @8 7EQ Di 3 3 3 3HE69BH 3#BEC 3 6 Q 7 8 6 ccEH G 78H A3 83 i Hh H 9 5 F93H 53C 37 36 Q9Hc I3 QH8 8EhHE7 6@ iF c9 A0c QH3 8"AH 8@ 78 i8 H"V8 A 6 D Q 6 H 6 D 5S P F P 3A I3 6 5E3B P 8Hh pC s # Q9H (6 AB W 3 U vaV q W T 3 Q 6 6 c A F P 3 WH c 6 Q p V p V 2p9 1Y yp 3B 6 Q 7 D 8 6BE i G i H8 Hh 9H 3 3a3EHC 369H h 6iHH Q3BC i6 Q 6 6 c A P Ec F P 9 i E V &39 7B r3 p V p 3 Dd 6 iH 6 i G 6 i Hg H 3 3 3 hi 6 6 c A H9 b99B 5 39E 3 G 7 Q 7 c 7 D e 5 g 5 d 3y 3 3 hr ci 6Q Q3 c# A6 6W QA iE6 D Q D c 6 D H BC6 V"Bs pE6 VG BD P 3BC3 3 cF 6D Qx D 8 8 H CA VD pB3 V3 P 5 3c 3EBF 33 3 388H bEBhD E 7G DEF Q6 i6 H3 c88 6E@ D9HQ" A9BA( DQ Q9Q 73 AP @ 7 8 D 99 U 9 9BEHc FD BA 5 5 Y V W W V T 3Q bF 35 3HH 3 h@ cHH69 69@ Q9b` Q@ Q3 7F G93 cF 6E6 8BH7 D6 cW AP D D 6 A D G f@99 9 VtbH pAD VHPH E93 BQ 5 F 5 3 3WD 3H95 8 4 @HCQ99B9 @@EB 6Eh93 7938 AH7H i QHX H83 @ D 6 P86C 59E@ 5 C h978 ABBI 7@ DE3r AQr DQE AB6EH DP iAH DP i8B8 HFE9 H3 # $ 9@ 9B68 9F99 50H TH39B)R VQ VC29E9BEEEE eE9D8 g@h B9PH9" &" d3BEC B 1 ( ' P #699 E3 6E99BB #P"H9 D9 #vEH sP9h f9EEH #Fa9E" B %9 9QH9 t !b B9h9 EHEE9 9H 9H 9 9 C 9 939 99 H6C "ES "DEBE9EH "i H
fitting location: in coat ignition not get into
-------------
------------
24
23
22
21
20
18
17
coolant t
of
clip
if
connection
of
in
of
of
off
of
ageing
30 F
28 Vacuum
27
24
34
33
32
31
Fuel
Warm air intake
fitting location: in if
engine
oil
attention to fitting location
Engine
Engine
line
to
Edition 03.01 S00.5133.50.20
OCTAVIA
OCTAVIA
2% '0 %) 3' $# 2%$ '( %& % ! & 1' # # $" $

24
and
1-
control unit testing page 24-16 if replaced, adapt engine control unit page 24-32
replace if damaged
6 - 20 Nm -
2 - 10 Nm 3-
replace
replace
4 - Inlet connection
Edition 03.01 S00.5133.50.20
------------
-------------
24
10
------------
& ' 3 6 # & $ 5 4 # # & 2 $ 3 # 1 '% % ! '( ' & ) %# 0'" 1 ( $
Fuel Formation/Fuel Injection 11 I i
OCTAVIA
ensure correctly installed replace if damaged
replace if damaged
testing intake manifold temperature sender page 01-43 specified resistance page 24-14, Fig. 2 testing intake manifold pressure sender page 01-42
12 I
13
acuum from fuel pressure regulator
-------------
Edition 03.01 S00.5133.50.20
OCTAVIA
u Y I I I Y S X I P c V V e G I R Y d y cx t u I X X S w y Q v s v wq v5 t s 0 B D % 4R 4 p p 7 p r V& efB aF`2gB d`xS#D( Xih9 a&Q3 GF``W8 YGFA# GFP(# I' R% X7 I6 QQS # QQq % Q# cFFuqIH3 cxb5 #C #S% # C4 BEA 21 %A ' 2( & U4 T@ A0 $ ) ( ! "
24
and
rail
ensure correctly installed replace if damaged
replace moisten clean engine oil
3 4
rail
ensure correctly installed at and at fuel rail
testing page desired resistance: ance increases ...6 engine operating ture)
Edition 03.01 S00.5133.50.20
------------
-------------
24
Fuel line white secure with spring strap clips ensure tightly installed from fuel filter: 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20 blue secure with spring strap clips pay attention to fitting location to fuel pump in fuel tank: 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20
------------
" % $ # ! " "

Fuel Formation/Fuel Injection 10
OCTAVIA
replace if damaged
11 Fuel testing fuel pressure regulator and holding pressure page 24-19 acuum
12
-------------
Edition 03.01 S00.5133.50.20
r @ 7 ( ) 7 1 ) 7 ) ) 7 1 3 ' ) 1 3 5 8 A bX C b5 e#6 A Sp5 U5 ' i5 A U# f' VA T# U6 V h U U U e W#G6 ( P57 g( aHc( QG' ' aB !@ )7 31 (0 ('# (' 5 5 d2 09 6 6 b#@ V57 IX" U) U3A V@ U7 Y3 V( `) % $ WXQq3 W4 VQQ'35# U! S6G) TQaH35 ID RQ6865 G! G75 WaHG#26' PHH7 (( 3( E7 F&
Edition 03.01 S00.5133.50.20
OCTAVIA
Filter element
air
and
air
ensure
------------
-------------
24
24
------------
$ & 1 " ' ( ( " ) 0 ( ( ! $ & % " ' # #

OCTAVIA
coolant
The chart is splitted to two temperature ranges: A - from 0...50 C B - from 50...105 C
Examples:
30 C is within range A, equals a resistance of 1.5...2.0 k
80 C is within range B, equals a resistance of 275...375
Connect multimeter for resistance measurement to contacts 3 + 4 of the coolant temperature sender. temperature
K Fi . 2
The chart is splitted to two temperature ranges: A - from 0...50 C B - from 50...105 C
Examples:
20 C is within range A, equals a resistance of 2.3...2.6 k
80 C is within range B, equals a resistance of 290...330
Connect multimeter for resistance measurement to contacts 1 + 2 of the intake manifold temperature sender.
-------------
Edition 03.01 S00.5133.50.20
T x T U X q T s tV qx T r T T q U q T U T U x X q u s W s d u ar wr X Xv r X X T r r X X X T Y T X d W X T U r r X r x X r X T r T Tr x y r x r q X U X T r r X T T q T V u s u va r X x X q T X s c y w w T q x r T X T X W u wU TU VV XT T y raVV qV T V U rV T T r U T r syV s XV ryt Xt r u Svy AV F A Q T T T q U T q e cVVt byVyv b `vv VV f d b W s p wV wy T T T x T r eU cVy bq by `y i da s u s T X Y e cyvt b i ` i g f d W Saayt Ray AP A Gh D PU G F A F P G @ D B A G A QaaaVyVy Q 9 Ca C 8 8 6 5 3 0B 0aa #yv # ( " ! '$ V " ! 2P 14 )P &I % vV V VaE t HV EvC a7
Notes: T The contact numbers of the connector and the socket numbers of the test box V.A.G 1598/22 are identical. Use adapter cables from adapter cable set for connecting the testers to the test box. t t and
------------------------
OCTAVIA
Edition 03.01 S00.5133.50.20
24
24
------------
7 % 1 $ % & 2 % 5 8 9 1 2 9 1 & 2 % 5 8 % 2 1 % 1 2 7'0 64 %4) %0' 20 ( 2 4 4 $ ( & 5% 54 # ' ! " 3) 0 0 ' ' 0
OCTAVIA
control unit
Components of throttle valve control unit -J338-: throttle valve drive -G186-, angle sender 1 for throttle valve drive -G187- and angle sender 2 for throttle valve drive -G188-. Note:
If the throttle valve control unit is replaced, it is then essential to adapt the new control unit to the engine control unit page 24-32. and
Hand-held multimeter, e.g. V.A.G 1526 A Adapter cable set, e.g. V.A.G 1594 A
l Throttle valve must neither be damaged nor dirty. l Coolant temperature at least 80 C. l Battery voltage at least 11.5 V.
K-
Measure resistance of throttle valve drive between contacts 3 + 5. Specification: 1.0...5.0
If the specification is not achieved: -
Replace throttle valve control unit (J338).
If the specification is achieved: -
Test voltage supply and cables to throttle valve control unit.
If the voltage supply and cables of the throttle valve control unit are o.k.: Replace engine control unit page 24-29.
-------------
Edition 03.01 S00.5133.50.20
OCTAVIA
K-
K-
Edition 04.02 S00.5133.51.20
F H P I G 0 1 " 0 A E D 0" ( 0 % $ 4 0 1 0 0 1 " 0 '9 ' ! 9 9 @ A C B 0" (% 0$ %$ $% 4 0 1 0 0 1 " 0 ' ' !' 9 9 @ 0 $ 1 0 " 8 0' ( " 0 ( 1 0 ! 8 2 % 2 4 " " $% 7 $ 6 % 5 % 0 " % # 1 0 !&& " 3 2% $ "9 %$ % 1 0 # % $ " " ( ( " ' ' ! ' ' & ' & ' '' & ' '& )
24 jet injection and
and and torque wrench adapter cable set, e.g. V.A.G 1594 A digital potentiometer, e.g. V.A.G 1630 measuring glasses, e.g. V.A.G 1602 l the fuel pressure must be OK, check it page 24-19. remove the engine cover t e For e pull out the 4-pin connector -arrow- from the ignition transformer. t e For e pull out all ignition transformers using the extractor T10094. For all pull out the 4-pin connector from the sender of the coolant temperature (G62) -arrow-.
------------------------
24
OCTAVIA
K-
Connect digital potentiometer to contacts 3 + 4 of the connector and set the connected side to 15k.
K-
Detach vacuum hose from fuel pressure regulator -arrow-. Detach wiring loom of the injectors at fuel rail. Remove fuel rail complete with all injectors from camshaft housing (the fuel hoses remain connected) page 24-11.
K-
Hold a measuring vessel below the injector to be tested and unplug the connectors from the remaining injectors. Have a second person operate the starter. The injector must eject in a pulsating spray. Repeat the test at the other injectors. When doing this, ensure that only the injector being tested is connected. To conclude, inspect the injectors for leaks. Not more than 2 drops a minute must drip out.
------------

-------------
If the fuel loss is greater: Switch ignition off. Replace the faulty injector page 24-4, item 4.
Edition 03.01 S00.5133.50.20
OCTAVIA
Fuel Formation/Fuel Injection Install the injectors in the reverse order. Pay attention to the following points: Replace the O-rings at all the injectors and moisten lightly with clean engine oil.
24
K-
Edition 03.01 S00.5133.50.20
3 ! & ! " ' 1 4 3# 20 !0 !) $ 0! ' & ! & 0 ' ' ' ! $ " 1! # 1 (% 0 % ) #
Insert injectors vertically into the fuel rail and into the correct position, and secure with retaining clips. Place fuel rail with secured injectors into camshaft housing and press in evenly.
fuel
regulator and
The fuel pressure regulator regulates the fuel pressure in line with the intake manifold pressure.
The specification for this test depends on the operating pressure of the fuel pump. Fuel pump pressure is approx. 3.0 bar (0.3 MPa). t t and
Pressure measuring device, e.g. V.A.G 1318 Adapter, e.g. 1318/10 Adapter, e.g. 1318/11
Adapter, e.g. 1318/16
Pliers for spring strap clips
Remove fuse 28 for fuel pump from the fuse holder. Remove engine trim panel.
Detach fuel feed line -1- and collect fuel which flows out with cloths.
Warning!
Fuel system is pressurized! Before slackening hose connections or opening test connections, place cleaning cloths around the connection point. Then, release pressure by detaching carefully.
------------
-------------
$ $ $ $ ' # # ' $ $ $ ! # 8 ! # $ $ " ! ! ! U # ' $ " ! 9 ! ! 1 2 ' 9 $ $ 7 ) ) 5 9 8 2 E ! $ " 5 7 9 5 ) ) 5 $ T "$ "" B ! $ " $ $ !" 9 $ % 3 $ B ! ! B % $ 3 ! ! $ S R 5 ) 2 E # """ $ $! " 6 6 H P( ! I % F $ D B " # $ !@ 1 ' $ " $ ! 2" " $ 4 $ 7"" 9 5T C" C 5 @ 8 $ 8" " ! B ! 9 A #" # ! ' " "" $" $ $ @ "! ! ! ! ! @ ( $ 3 !" ! 2 $ 6 6 7 9" ) ) 5 @ 1 2 T $ " 3 "" 1 ""( " ! "" $ $ $ !3 0 ) Q "" '4 $ $G $# $ " & " 3" " "" "" $ $ $ % ! ( " " ( " 8 " ( " " " " " ""
-------------
------------
24
K-
K-
K-
Connect
At
not
to
to
Edition 03.01 S00.5133.50.20
OCTAVIA
0 ' 0 $ 9 $ A ' 0 9 (0 ' 9 1 ' ! 6 ' 0 4 9 9 1 0 C '0 C $ G 1 6 D 1 F 0 I ' 1 F C 0 1 1H G 1 1 E 8 ( '( ' 9 9 9 C P( @ 0 ' 9 D 0 9 A @(8 ' ((( H ( 0 0 $ 1 ( 8 ( ' @ 9 1 5 4 7( 6H ( (( (38 0 0( '( # # %(( )((( 2 1 & $ ! (((8 BB ( (" (( (
Before disconnecting the pressure measuring device, place cleaning cloth again around the loose hoses of the feed line. Note:
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OCTAVIA
Edition 03.01 S00.5133.50.20
KK-
24
24
------------ 24-22 -------------
B 1 % ) 2 2 17 0(9 & (@ "5 &4 (&3 8 &A % % ( & &6 " )5 !( )$5( $ ! $ '$ !$ # #
OCTAVIA
for
Notes:
The leak detection spray is inducted with the unmetered air as a result of the vacuum in the intake system. The leak detection spray reduces the ignition performance of the mixture. This results in a drop in engine speed and in a change in the lambda probe value. It is essential to observe the safety precautions stated on the can. and
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Engine leak detection spray G 001 800 A1 condition
l Coolant temperature at least 80 C Read measured value block 004, display zone 3.
Connect vehicle system tester V.A.G 1552. Start engine and select address word 01 Engine electronics page 01-4.
Read measured value block 1
00111111
K Check in display zone 2 whether the coolant temperature is more than 80 C. Observe lambda control in display zone 3 and engine speed in display zone 1.
Spray the parts of the intake system systematically with engine leak detection spray.
If the engine speed drops or if the lambda control value displayed becomes greater: End output and switch ignition off.
Inspect sprayed point of intake system for leaks and rectify any leak.
Edition 03.01 S00.5133.50.20
OCTAVIA
Edition 03.01 S00.5133.50.20
V 98 U 6 R7 B 9 7 P T 7 T 8 7 B 9 6 R P R @ D I S Q8 E 96 78 7 P7 B 9 7 6 G 5 F 5 7 F 5 B 5 9 5 I D 3 2 $ ! 1 08A& )C ' ! 'P $ # # ' $ $ $ ! ( ( C@ HR @" 8 A @ &" A8 A4 @%"HA

24 air
t t and Refrigerant spray e control Remove air filter. Check position of control flap. If temperature more than +23 C, flap must seal off warm air connection. If temperature less than +10 C, flap opens the warm air connection. Note: The t the
------------------------
h W E hE h Q RI DF D W i D SW P I I c v i F d X q c c R w I W D i q q r U I I D r v E q D i I v F H I W D Y x X y e cE RE qF W Q D c wv i q I R v D I Uc R r D I D F t F 0 g 3 0 7 f D q I D I I F F D c w i E q D I c v F Q DI IR cv IR E Di I q c D D UI i Sc FH F I q D q U E q v F F F I I D r v E q D i I c v Fi H I W D c Y ` X y EE Dy c R q W i D c w I eh pR yi FF p0 pPS yr `S p y y p y H t g 7 gTT 6TT ) 6 3 0 f IF Ev qUTPU DGTU Q cTU D w i q I R v D I D FS e y y t F DR Ir Q I R D I c I X v FFG y x D DS I I E E D w v FTGSTTT HVP F F s R D I i D u I q H IG W D q r h I R Q IT9 qPU IU cP5 qP c R UU i U Fv p e gT2 6 75 g 6 1 7 @ f b I c D WU I Yi e0 di XTSSTTT F C QPSG QU I I I R I E D U WU YPi aUGT Ì X0 F H F Bi AVTUV 0U9PT 0TVVS 7U 35 7 9t 9V5 3 9 0 7 6 0 6 7 @iTT @V5 ( 20 2U &TG # $ ) ' %$ #U2 S2S TG $P "I !1 ! "P2 ! US5 SUP SS5 PT5 P54 PS 4P2 8 S2 $
Test resistance heater, also cables to resistance 1...5 ) low Electrical Locations. l l Coolant l Battery Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
------------ 24-24 -------------
24
Kl
control
the
the
the
the test.
in converter
cable set,
a test in on the
be in
at least 11.5 V.
are not
are not
in the test:
system between catalytic
and of catalytic con-
and
at least
V.A.G
V.A.G
to eliminate any
is also not
Edition 03.01 S00.5133.50.20
3.
OCTAVIA
D m B G R # % ( & 2 x 8 G 1 8 G G 8 G 1 f A #( ( ) w 4 2 ( % ' 8 1 H G G 0 r 1 R R ) ( 2 % v 1& G t u # # 4 ' # ( 1 1 1 q ) E ' 45 # ' % 2 4 2 2 ( # % 0 $ 2 & ( 5 D I B B o ) ( ( # % % 1 0 H i & 2 D 7 l I H 9 B l 0 p ) ) & % D 7 l I m2 B 1 R ( D D o 7 l 8 8 l I 8 B 8 ) 2 2 4 2 E 4 '2 D D 7 l I m B I 0 f k' j$ A h h i! e i' x x# x xU y y$" r y y r "$ y 1 8 xUh x x ys$ $ y "S 5 w Y c r s v$ r g$ ux f' r f u f c Y ` aA a i e g g f1 fA r Y p f d c f iy h h"$ i h X # 7"$ 9 8 )A )$ A2 ' 44 ( '' % 2 ( 2 0 1 0 3A " 5 # ' ( 2 ' 1 & # # # # ( 2 ( ' W S S 1 R )U %x e E AA '' 'A & 2 ( & S VA T S $B $( # ( Q !0 )$ ) ( AA '# "" U % 2 ( ( A 0 1 0 3 AU$$A U! n 5 ( # ' # ( 2 1A"A E ($" # ( # & # ( ' D Ig G G G G G H G ) ` & (h d 5 ' 2 % 2 # # & 0 1 E & ) # % ( # ( ( ( ' ( y (Y t$a #Y #5 (2 '# (A '4 # ( 2 ' ( ( ' ' C # D 3 B )' )q # ) bq #5 q ) q %F$ A 2 & ( ( 5 u % 1# 7 9 8 )3b # #' (' ) 5% A"3"3 'Ua6 '' 4A3@ ( A 'A$ 3 % 2 ( 2 0 1 0 3" (' # #' (' A!"a #' #$""A@e ("" '2 &"6 %A F ' #" $" $F ' "' $"" $""$"3 ""$$"3 AP """P 3" "3 ""$U""$" ""$$ " "$
l l l
OCTAVIA
Edition 03.01 S00.5133.50.20
Kl
K-
control
Use
and
and
------------ 24-25 -------------
A t
24
24
------------

OCTAVIA
If the specifications are not achieved: -
Conduct a road test in order to eliminate any residues on the lambda probe, and repeat the test.
If the specification in the display is also not achieved after a road test:
Read measured value block, display group 041 page 01-58.
If the specifications are not achieved: -
Test resistance of voltage supply for heater, and also cables to -Z29 (specified resistance 1...5 ) Current Flow Diagrams, Electrical Fault Finding, Fitting Locations.
K-
Separate the 4-pin plug connection to the lambda probe downstream of catalytic converter (G130) -arrow-.
K-
Set multimeter for voltage measurement and connect to contacts 3 + 4 of connector at wiring loom to control unit. Start engine and measure basic voltage Specification: 0.400...0.500 V Switch ignition off.
If the specification is not achieved: -
Test cable of lambda probe downstream of catalytic converter Current Flow Diagrams, Electrical Fault Finding, Fitting Locations. If the specification is achieved: -
Replace lambda probe downstream of catalytic converter (G130).
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Edition 03.01 S00.5133.50.20
R B Q V R B Q b v V Y p Q B S X x V i R b i B Y Q b v R d Q p e q q A S S x V@ iV Q V i w Q V p Q V R B R d i S S G q Wb D V Y Q b R B p t V e q st D d Tt u B V p Q p R Q V R d Y R V RR q S S S S V V t V w U 9 ' 2 & ' ( 7 h h R B Q p B t Y R Y R S hA s h x iT QB Q Y p Q R V i cWR B Q Y R V p B x u x B V V t p i p V S U A yV YV Rf Rt B R B t V b b i V V c S S uG Bt X V u t u p B R c S U wV Bb Sq x RRd QR YtV pY Rrci VqS RFQ BcXp pWIV bw BQ t c q SVQ UtS Vx Yq Qred Brre wG VV bd Bi bt Vx SWBW sAW VdW RWr R Q t R R B V p R R B t Q U U V Vr b B b R ScT s ud BrV vU R' QXd Vyrr R5 Y R V R V V V R B V p R R B t Q SV AR SXc A U DWr h Vi VdrcT b6r B6 bcyy Rrc dR dr3 R Q dv drd V p St FWc Ic Sr q gr 2 3 g 2 ( 3 7 f Dcdrr a YX VX V b Q Eycc ew Frp S Dcd P V Y V R Q EWp `t Irrcrc S U S Dc @ B C E A IrW Irr G F 9)dW 8dc 'dd 'Xd 3H) 0 6' 3 2 ' 2 6c 3 & 0 3 ' 7tr 7drr) % )r "c5 !5 !d c 1W ) r ' Wp Xdc ( 5d rX1 4c $d rT 6d #Xc
4 C Fuel Formation/Fuel Injection C K est battery Kl l l l Battery such as l All electrical rear heater, must be l l Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
OCTAVIA
Edition 03.01 S00.5133.50.20
control unit
Select
must be
Start
est
control unit
cable set,
V.A.G
is
low
multimeter,
at least 11.5 V
at least 11.5 V.
system tester V.A.G 1552. select
must be
and
water
with air .
V.A.G
V.A.G
lectrical
2).
must be
------------
-------------
24
! 0 d ! ! a # ! ! ! a ! $ 1 1 ) ( ( ' 0 0 9 ! ! ! ! ! 1 1 ) % ( ' 5 0 ' R B B C Q C V B C I B I V C E 9 9 ! ! ! ! % 78 ! ! ! ! 9 ! ! ! ! ! ! ! ! ! ! ! g 6 a! ! ! ! ! %% !a ! !6 ! ! ! 66 a ! v u x x w s v w u6 x w u u u 6 t y i f f $ 9 68 ! 6 6 ! ! fs g f 8 8V 96 a ! 6 #6 e 96 !" !" 6 ! 6! ! 6886 ! % 8! h 8! !8 ! " ! ! 8 ! ! 14 ' 0h8 0h d d % ! B ! ! c8 c rU r " ! 3" 586 5 5 5 b % ` 9D 9E Q EP P 9 aS !hD D ! " ! ! ! Wh888 F6 Q6 S B S R T G C I B G Q F V C B q66 D p8868 8 f f i $ ! h" ! 8 6 ! 98 ! f! g f 8x 8 " 96 6 & ! 686 #! ! ! 88 E e 9ss ! ! s # ! 6! ! 6 ! h % 8H 86 !s ! " ! h ! ! 1 '88 06 06 d % ! #86 ! ! c c 1 1 ! 366 5 0 0 5 b % ` 9 98 A ! 9 a8 ! P ! " ! ! ! ! W F8 Q S B S R T G C I B G Q F V H C B D Y6 X8# P E A 1 0 @ 5 ! 6P 9 h ! ! ! 6 $ 7! ! ! & 68 ! & 1 6 )P 46 (D 58 ' 5 3 2 0 % !6h8 !P 7 " D ! ! ## U 6 P 68 888D8E UDE 8 68 6 8
-------------
------------
24
Procedure
Procedure in
and
Edition 03.01 S00.5133.50.20
OCTAVIA
) " " " 3 4 ) 5 " ( & ) % 1 0 ) ) q 3 5 ) ) 4 ) # F F r $ 1 ) " " ) # " ) " 1 v y x d w u q 3 F F t r ' ' ' ' 1 1 q q 5 ) F F r 6 $ 1 !) i! h Y Y g d d g e X b p W V U P S R H G & ) ) 1 '! 1 0 500 5 3 ' ) F $ 0!00 0 'F2 ' &9 501 0 "1 )0F 0 '0 00 @ $0 )! 0 " ) 0' " # " " ) E ! " E D ) ! 5 ) 59! ) # ) " ) ) ) Y 6!! B & 5 ! " ) ) ! 4 3 0 @ 3 5a 5 5 " ) ) " 8 8 ) 9I s &!8 a! Y ` 4 ) ) ) ) 7 " $fc %ca $ & ) T 4 Q ) 4 ) 7 5 " 5 # ) 6 6 3 # #" " ) 4 " ! ( # & 8! ) $ 2 1 0 !! ! " $ ' % $ 8! C ! )!! # #! "! ! & ) 8 A ! !& ! !! ! ! ! !!!
Fuel Formation/Fuel Injection K t
OCTAVIA
Edition 03.01 S00.5133.50.20
engine control unit
testers and aids
------------
-------------
24
a % H H 4 Q Q Q Q f f H ( & 4 #" " I f w w @ B @ w @ y w y @ v B u D q r q s r q s h g i 6 ) f Q f T 3 $ ) ) I 5 f T $ 6 ) & ! 5 f T ! x & & & ! ) ( S c $e$ !e$ & 4( 3( 5 d$( H 6$ D AC w A ! ) a $$DAC & ! ) & 1 " # 7 H S ` 1 X Y & ! G P ! ) W P T S ( )( ! ( ( # P T V H 6 6pp e ! ) ! (R (# " ) ! I Q P I H # ! ) ( ( ( " (( ( ) G " 2 (((( (F ! 2 ( " E 9 9 B ! 7 (( ( )( ( ( ! & ! (( " " ! 6 )& !($( ! F $ ( 1 3 " % ) T T & $$ !US 5 ((T T $ P y$ 0 4(T($ 3G5( 56(( 5Q$ 'T 1f d (( ( # ! & #(P( ") W 2$(F 8 (C @ ($(A & D (( ( ((( ( (( G (( (C ( (( $ ( ( (
-------------
------------
24
K-
Notes:
If the code displayed does not correcpond to the vehicle, or if the control unit has been replaced, it is then necessary to code the control unit as follows.
During control unit identification a 5-digit code must always be displayed.
control unit
and
Edition 03.01 S00.5133.50.20
OCTAVIA
5 1 4 3 4 3 2 3 E A 6 9 5 5 5 A 3 A A 6 5 Q6 ! 1 5 3 4 3 E 3 "3 4 65 P 6 6 5 5 5 5 ! A r A A x G 6 5 5 A 3 3 4 3 3 E 4 3 4 3 3 6 6 5 5 5 2 3 G 0 u P 6 9 w v 5 5 5 Q 1 4 r 2 E 3 " tb 0E 97 07 s % q P `7 ' a 5 56 5 5 5 1 26 4 r 2 E 3 "D " q P$ P ' ) 7 7 G 0 u 9 w v 5 5 5 Q 1 4 r 2 E 3 " t" 04 94 07 sb % q P `4 ' ' 7 7 5 5 5 4 r 2 " E 3 P q ' 7 7 p7 e D W f d i7 i" i g g c T hE V4 h U W R 5 $7 ! 1 h 3 3 4 3 6 I5" ! E H3 6 5`"4 4Ay4 3 "1 !$" 23 33 4 E E3 36 4E 3 I3 P$ ! DA4 b 5 P3 P5 94 63 !DH 1P 3 I H 5 3w 37 E 4 3 47 " 4 3 4 3 E F 62 @ G 6 7 0 572 $"" 4 BV73 06 27' A"G 3a 4) q 7 7 7 3 2 3 '" $ 77 9 ' 7 C4 $ 5" a 57 1$7" 4Y DQa "7) S' 3(7 "$( 3QF 49 37 " 2 1a 6D3 68DY 6"84 6"3 0 $" $T Da4 XY Q" Y !! V DU " " (3 (43 &@)6 %"76 #Y )4 '"74 bE ` " P 3 E 9 B G
or Fuel Formation/Fuel Injection K K K The Motronic control unit does not use the code entered and which appears in the display until after the ignition has been switched off once for at least 15 s. Incorrect coding results in: Notes: Traction control system on FWD vehicles not operating (TCS/ASR warning light on) Functions not being performed (lambda control, actuation of activated charcoal filter system, etc.) Storage of non-existant faults in fault memory Increased emission levels Increased fuel consumption Vehicle performance problems (jerky gear changes, load change jolts etc.) Connect r n on t enter to
------------------------
OCTAVIA
Edition 03.01 S00.5133.50.20
24
24
------------
6 ( ) 6 ( # ) " 5 2 4$' 3$ "1$ " ) % ) 1 1 ! % # " ) ( " ( ) 2" 2' $ ' '& 0 '&$
OCTAVIA
As a result of the adaptation, the engine control unit learns various positions of the throttle valve when the ignition is switched on and the engine is not running. These positions are stored in the engine control unit. The feedback signals of the throttle valve position are provided by the two angle sensors for the throttle valve drive. Adaptation must be performed if:
the voltage supply has been interrupted
the throttle valve control unit has been replaced the engine control unit has been replaced
another throttle valve control unit has been installed as a result of installing a different engine. and
l Ignition on, engine not running.
l There must not be any fault stored in the fault memory page 01-6, Interrogating fault memory. l Battery voltage at least 11.5 V.
l If vehicle is equipped with air conditioning, this system must be switched off. l All electrical components such as lights and rear window heater, must be switched off. l Throttle valve control unit must be in idle speed position. l Throttle valve must not be dirty.
l Coolant temperature at least 5...80 C Read measured value block 004, display zone 3.
-------------
Edition 03.01 S00.5133.50.20
OCTAVIA
Edition 03.01 S00.5133.50.20
0 3 2 3 2 1 ) 4 D 3 D @ D 3 8 1 2 H X 4 4 4 4 4 22 3 @ 1 2 2 3 5 5 F 6 S 4 4 #5 2 3 @ 3 @ 3 D D 4 $ 54 5 4 4 4 2 3 T 5 3 V W $ H 2 D V W $ 4 4 2 3 @ Q 2 2 3 @ B 5 ) 4 4 2 3 @ Q 2 2 3 @ T S 5 ) U 4 4 2 2 3 @ Q 2 2 B 5 S 5 4 F 4 R 3 3 2 3 @ ! ! 4 # 1 2 3 3 ! Q 5C 5 45 @ 2 # 3# ! 1 2 @ I H $ 4 @ D 3 1 @ 6 5 6 G 43 4C! 4 2! 1 23 ! 2! 2 3 2 D T P 5 9 2 F B 6 ) 4C! #2 AAE a 1!a @! 2# 3 7 2 ! 1 2 & 67 8 & 6 B3 4C 4 0b 3B d !! 2 !@ 2# 3C 2 ! 1 0 5DF 5E 5 5C# ) #c # #@ ! CC C C ! ! ! ! f 'H '& %9C) $C "#4 ( &C C2 1 ' 6 G U e Ee2
24
Connect
on
enter
been
to
Notes:
If the basic setting is aborted by the engine control unit, this may be for the following reasons: the throttle valve is not able to reach the mechanical idle speed stop because of dirt, e.g. oil carbon deposits, or because of a mechanical fault. the battery voltage is too low. the throttle valve control unit or the cable connection is faulty, test page 24-16.
After an aborted basic setting, the fault is stored in the fault memory. The next time the ignition is switched on, the basic setting is automatically repeated.
------------
-------------
X W U x U r s s w U r U U U s f D U U Y T T B X rs W U U D U U Y r s D U s r r f D w Tf T X W D r s U D Y s W U U s T T W r b R tes X X W s Y s W Wu sT U x p U D T Vr r D U D r D U U U U W q r D r D r b U D r W G T X Uw Ds r U ww U sf U Y W U D U r r w eD cD C T T G Q br YU rSet S D r D U r b r w U f r tf b fw D E U r D G Qe Q I H F C SW D UU U w p Y D D r U D D W VeS T T T UV W r w D r U U Y U s U w r Teee T T Y D b G Ws Yg xw re sp WV X D U w W U p W U U Ts Ta C T Ve AVSS ) 5 ( ) 0 6 ) 9 h S W b r W b D U r F Xf Xee UT bW Wb YSw De Ut xfe W U r U D f W s D T q v XS U W s x U w Ya D W Y U f f eVVSt p He X U U D Bt q ts UfaeSe XS UeaSt YSee bVT rSSe sP U U s D U Y D Y r U U D U U Y f TFS T T USt b W D p i 5 6a i 5 0 6 ) 9 h d b U U Y W G geSeS HVt F T R Xu U Y W U D b GSf ce Qf FVS T B D E GVS Qef QVat Ie Hf F C ASeV4` @8V )8e )eu 6f 2f 64 8w 88 ( 2 0 )4 6 5 ) 5 6 9) 9yt ' 1f e " eV`SS31 ee &41 e $4 #1 e3 7VV ! %f #1fe aeS P4VSVS af fee Saf af
-------------
------------
24
The right front wheel must not be rotated during this step.
Note:
l Battery
the
est cable also to
est
test loom to the
test l
test
cable set,
additional
V.A.G
wheel.
at
test l
at least 11.5 V.
V.A.G
is
and
V.A.G
as the
to
V.A.G
memory.
short
to the a e
or
the slows
Edition 03.01 S00.5133.50.20
OCTAVIA
OCTAVIA
K-
Edition 03.01 S00.5133.50.20
D 7 # & 3 C1 A 7% ## A 7 ) # ( & 7 5 # # ) & # 1$ 1 @%) @1 3 B @ % D 7 # & " # # # 2 E 3 @ C# A1 7$ A 79 )%9 #E9 ( & 7 5 # # ) & # 2 1# 1 1 @# 32 B% %" %) @ %2 % 5% #1 ( " # $ ) # 3% 6 79 (1 )%8 7 ( $ ) 38 6 5%2 42 #2% #% )1 &1 2# ) ( # ( 2 ) " & $ ) # 3# 31 ! % 1 0' '%
24
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Refer to the appropriate current flow diagrams to determine which control units are connected to the drive databus (CAN; Controller Area Network). Check the plug connections of all the connected control units to ensure they are tight. Connect vehicle system tester V.A.G 1552 and enter function 00 Automatic test sequence. Before testing the communication line, determine whether there is any operational fault at the connected control units. t t and Test box V.A.G 1598/21 Hand-held multimeter, e.g. V.A.G 1526 A Adapter cable set, e.g. V.A.G 1594 l A fault has been detected at the databus by the self-diagnosis. Connect test box V.A.G 1598/21 -1- to the wiring loom of the ABS control unit -2-. Test terminating resistance in engine control unit. Measure resistance between sockets 10 + 11 of test box. Specification: 60...72 k. not Replace engine control unit page 24-29. - Test databus Electrical System; Repair Group 90.
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OCTAVIA
Ignition System
Servicing ignition system

General information on ignition system
28
Do not disconnect and connect the battery unless the ignition is switched off otherwise the engine control unit may be damaged. The engine control unit is equipped with selfdiagnosis.
This section deals specifically only with the components related to the ignition system. For the other components of the fuel injection and ignition system from page 24-4.
Components marked with * are tested by the self-diagnosis page 01-6, Interrogating and erasing fault memory. A voltage of at least 11.5 V is required for proper operation of the electrical components.
When conducting certain tests, it is possible that the control unit will detect and store a fault. For this reason, after completing all the tests and repair work, interrogate the fault memories and erase if necessary page 01-6, Interrogating and erasing fault memory.
Before commencing repairs and fault finding, interrogate fault memory page 01-6, Interrogating and erasing fault memory.
If the engine starts only for a short time and then cuts out again after conducting fault finding, repairs or tests of components, the reason for this may be that the immobiliser is inhibiting the engine control unit. In such a case, it is necessary to interrogate the fault memory and to adapt the control unit page 24-32.
Safety precautions page 28-1. Test data, spark plugs Inspection and Maintenance.
Safety precautions
Pay attention to the following points in order to avoid injuries to persons and/or damage to the fuel injection and ignition system: Do not touch or disconnect ignition cables when the engine is running or operating at starting speed. Do not disconnect or connect cables of the fuel injection and ignition system - also not cables of test equipment - unless the ignition is switched off.
Edition 03.01 S00.5133.50.20
------------ 28-1 -------------
28
The ignition system
OCTAVIA
Please observe the following if it becomes necessary to use checking and testing equipment when undertaking a test drive: The checking and testing equipment are always to be fixed to the rear seat and also to be operated from there by a second person. If the checking and testing equipment were also operated from the front passenger seat then the person there could suffer injury from the airbag if a crash occurred. When the engine should be run at the starter speed without firing: For engines with engine identification characters AXP Kpull out the 4-pin connecting plug from the ignition transformer -arrow-.
For engines with engine identification characters BCA pull out all ignition coils using extractor T10094.
For all engines Kpull out the connecting plug on the injection valve -arrows-
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Edition 04.02 S00.5133.51.20
OCTAVIA
The ignition system
28
Removing and installing parts of the engines with engine identification characters AXP
3 - Connector black, 4-pin for the ignition transformer (N152)
1 - Ignition lead with shielded plug and spark-plug resistance 4.8 .. 7.2 k
2 - Ignition transformer (N152) with identification for the ignition leads: A = Cylinder 1 B = Cylinder 2 C = Cylinder 3 D = Cylinder 4 page 28-4, Figure 1 checking Installed location page 24-5
Edition 04.02 S00.5133.51.20

4 - 10 Nm 5 - Connector black, 2-pin for the knocking sensor 1 (G61) contacts gold-plated 6 - Knocking sensor 1 (G61)* contact from the sensor and the connector, gold-plated installed location page 24-4 7 - 20 Nm the tightening torque has an influence on the function of the knocking sensor 8 - Connector black, 3-pin for the hall sender (G40) 9 - Hall sender (G40)* Page 28-6 checking installed location page 24-5 10 - O-ring replace when damaged 11 - Spark plug, 20 to 30 Nm removing and installing using a special spark plug wrench (e.g. 3122 B) Injection type and change interval and Maintenance 12 - Ignition cable strip holder
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28
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" !
The ignition system
OCTAVIA
the
check the secondary resistances on the terminal between cylinders 1 + 4 and cylinders 2+3 Nominal value 4.0 .. 6.0 k (at 20 C).
If the nominal value is not achieved: -
replace the ignition transformer (N152).
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Edition 04.02 S00.5133.51.20
OCTAVIA
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The ignition system
28
o the engines with engine
black, 2-pin for the knocking sensor 1 (G61) contacts gold-plated
contact from the sensor and the connector, gold-plated installed location page 24-5.2
the tightening torque has an influence on the function of the knocking sensor
black, 3-pin for the hall sender (G40)
checking page 28-6 installed location page 24-5.2
replace when damaged
black, 4-pin
remove and install using an extractor -T10094-
20 to removing and installing using a special spark plug wrench (e.g. 3122 B) type and change interval Injection and Maintenance
Edition 04.02 S00.5133.51.20
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28
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The ignition system
OCTAVIA
the
ing
testing
testing box V.A.G 1598/22
hand multimeter, e.g. V.A.G 1526 A
adapter cable set, e.g. V.A.G 1594 A Testing
battery voltage at least 11.5 volts. Testing
K-
pull out the 3-pin plug from the hall sender -arrowsconnect up the hand multimeter for voltage measurement to contact 1 (plus) and 3 (earth) of the plug. switch on the ignition: Nominal value: at least 4.5 volts switch off the ignition:
K-
If the nominal value is not reached: -
check the cable connections to the sender according to the current flow plan Current flow plans, Fault Detection Electrics, Installed Locations
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Edition 04.02 S00.5133.51.20

Manual Skoda Octavia 1,4 55kW

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Service

Workshop Manual OCTAVIA

Service Department. Technical Information

Edition 03.01 04.02

Article Number S00.5133.50.20 S00.5133.51.20

Table of contents next page

Printed in Czech Republic S00.5133.51.20

01-1 01-1 01-2

24-1 24-1 24-2 24-3 24-4

24-24 24-24 24-25

24-15 24-15 24-16 24-17 24-19 24-22 24-23

24-5.1 24-6 24-9 24-11 24-13

24-27 24-27 24-28 24-29 24-30 24-32 24-34 24-34 24-35

Edition 04.02 S00.5133.51.20

The ignition system

Edition 04.02 S00.5133.51.20

General information on selfdiagnosis

Edition 03.01 S00.5133.50.20

------------ 01-1 -------------

01 Technical data for the self-diagnosis

Motronic ME 7.5 EU4

Variable intake manifold length Camshaft adjustment Secondary air system

Exhaust gas recycling system

01 Ask about the control device version 03 Actuator diagnosis

Yes 1) Yes Yes

Yes Yes Yes No No

08 Read the measuring block

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

Edition 04.02 S00.5133.51.20

K Installation position of EPC warning light

Edition 03.01 S00.5133.50.20

Test of vehicle systems Enter address word XX

Edition 03.01 S00.5133.50.20

036906032 ME 7.5.10 Coding 00021

3257 WSC 08686

Storage of non-existent faults in the fault memory

K Readout in display: Workshop Manual for further procedure.

Edition 03.01 S00.5133.50.20

Only if engine does not start:

system tester V.A.G 1552. select the with the 1

Edition 03.01 S00.5133.50.20

Test of vehicle systems Enter address word XX

Edition 03.01 S00.5133.50.20

16497 = fault code

Rectifying fault - Test sender -G71

Intake manifold pressure/air pressure G71-/-F9616492 signal too large

Intake air temperature sender -G42 16497 signal too small

Coolant temp. sender -G62 implausible signal

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

Edition 03.01 S00.5133.50.20

Bank 1 probe 1 16516 voltage too small

Bank 1 probe 1 16517 voltage too large

Bank 1 probe 1 16519 no activity

Bank 1 probe 1, heating circuit electr. fault

Edition 03.01 S00.5133.50.20

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

electr. fault in circuit 1

voltage too small 1

voltage too large 1

signal too slow 1

electr. fault fuel

system too lean

Edition 03.01 S00.5133.50.20

Edition 03.01 S00.5133.50.20

# 5 6 3 3 ( & # 5 6 3 3 # 5 4 6 34 3 1 2 1 3 3 0 $ % % ) $ % % ( $ % ' $ % 4 2 # # # #""""!!!! & ' 7 4 ! 4