Manual Skoda Octavia 1,9 81kW

Service
Workshop Manual OCTAVIA

1.9-ltr./81 kW (TDI) Engine, Fuel Injection and Glow Plug System
Service Department. Technical Information

S00.5122.50.20 Edition 03.98
The Service Manual is intended only for use within the koda Organisation; it is not permitted to pass it onto third persons. 1998 KODA AUTO a. s.
Printed in CR
Service
List of Supplements to OCTAVIA Workshop Manual
Edition: 01.04
1.9l/81 kW (TDI) Engine, Fuel Injection and Glow Plug System

Replaces List of Supplements - Edition: 10.03
Edition 02.99 02.01 01.02 10.03 01.04 03.98
Supplement
Subject
Modifications to Fault Codes Modifications to Vehicles 08.00 Supplement to fault code Readiness code, Supplement to Repair Group 01 Supplement to Repair Group 01 Basic Edition
Article Number S00.5122.51.20 S00.5122.52.20 S00.5122.53.20 S00.5122.54.20 S00.5122.55.20 S00.5122.50.20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Contents next page.
The Service Manual is intended only for use within the koda Organisation; it is not permitted to pass it on to third persons. 2004 KODA AUTO a. s.
Printed in Czech Republic S00.5122.55.20
OCTAVIA
01 Self-Diagnosis
Contents
Service
Page
Measured value blocks ............................................................................................................... - Reading measured value block ................................................................................................ - Display nominal values for general vehicle inspection ............................................................. - Display nominal values for injection pump ............................................................................... - Display nominal values for engine idling .................................................................................. - Display nominal values for exhaust gas recirculation .............................................................. - Display nominal values for temperature sensor ....................................................................... - Display nominal values for automotive power .......................................................................... - Display nominal values for charge pressure control ................................................................
Readiness code ........................................................................................................................... - Reading readiness code ........................................................................................................... - Generate readiness code .........................................................................................................
Actuator diagnosis ...................................................................................................................... - Performing actuator diagnosis ................................................................................................. - Basic setting ............................................................................................................................. - Coding control unit ...................................................................................................................
Self-Diagnosis .............................................................................................................................. - Properties of the self-diagnosis ................................................................................................ - Technical data of self-diagnosis ............................................................................................... - Connecting tester V.A.G 1552 and select engine electronics control unit ................................ - Interrogating and erasing fault memory .................................................................................... - Fault table .................................................................................................................................
01-20 01-20 01-24 01-26
01-1 01-1 01-1 01-2 01-5 01-8
01-27 01-27 01-29
01-31 01-31 01-32 01-36 01-42 01-47 01-48 01-49 01-54
23
Fuel Formation/Injection
Servicing a diesel direct fuel injection system ......................................................................... - Safety measures ...................................................................................................................... - Rules for cleanliness ................................................................................................................ - Overview of fitting locations ...................................................................................................... - Servicing injection pump .......................................................................................................... - Servicing fuel filter .................................................................................................................... - Servicing throttle mechanism ................................................................................................... - Adjusting sender for accelerator pedal position ....................................................................... - Disassembling and assembling air filter ................................................................................... - Removing and installing injection pump ................................................................................... - Dynamically testing and setting commencement of injection ................................................... - Removing and installing and testing injection nozzles ............................................................. - Replacing O-ring at cover for injection timing device ............................................................... - Wiring and Component Test with Test Box V.A.G 1598/22 ...................................................... - Replacing engine electronics control unit ................................................................................. Inspecting the charge air pressure system .............................................................................. - Inspecting charge air pressure ................................................................................................. - Inspecting charge pressure control solenoid valve (N75) ........................................................ - Inspecting intake manifold temperature sender (G72) ............................................................. - Inspecting intake manifold pressure sender (G71) and altitude sender ...................................
23-4 23-4 23-6 S S
23-1 23-1 23-1 23-2 S S S S S S S S S S S
Page
S Repair operations 1.9l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Vehicles for Model Year 98 (08.97 )
Edition 01.04 S00.5122.55.20 ------------ I ------------
Service
Inspecting control units input quantities .................................................................................. - Testing voltage supply for diesel direct injection system .......................................................... - Testing engine speed sender (G28) ......................................................................................... - Testing needle lift sender (G80) ............................................................................................... - Testing coolant temperature sender (G62) ............................................................................... - Testing brake light switch (G149) and brake pedal switch (N146) ........................................... - Testing modulating piston movement sender and metering adjuster ....................................... - Testing accelerator pedal position sender (G79) ...................................................................... Testing auxiliary signals ............................................................................................................. - Testing signals from/to the air conditioning system .................................................................. - Testing clutch pedal switch (F36) ............................................................................................. - Testing speed signal ................................................................................................................. - Testing engine speed signal ..................................................................................................... - Activating or deactivating cruise control system ....................................................................... - Testing cruise control system ................................................................................................... - Testing databus ........................................................................................................................
Inspecting exhaust gas recirculation system ........................................................................... - Hose layout plan for the charge pressure regulation, the exhaust gas recirculation and intake manifold flap .................................................................................................................. - Inspecting exhaust gas recirculation ........................................................................................ - Inspecting electromagnetic exhaust gas recirculation valve .................................................... - Inspecting air mass meter (G70) ..............................................................................................
Testing injection control ............................................................................................................. - Testing injection timing device control range ............................................................................ - Testing the commencement of injection valve (N108) ............................................................. - Inspecting fuel temperature sender ..........................................................................................
OCTAVIA
S S S S S 23-9 6 S 23-10 S S S S S S 23-13 S S S S S S S S S S 6
Servicing intake manifold ........................................................................................................... - Inspecting the change-over of the intake manifold flap ............................................................
28
Glow plug system
Inspecting glow plug system ..................................................................................................... - Inspecting proper operation ...................................................................................................... - Inspecting glow plugs ............................................................................................................... - Inspecting glow period warning lamp .......................................................................................
Page
S S S S
S Repair operations 1.9l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System, Vehicles for Model Year 98 (08.97 ) 6 Repair operations 1.9l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System, Vehicles for Model Year 98 (08.97 ), Hose layout plan 1.9l/81 kW (TDI) Engine, Fuel Injection and Glow Plug System; Page 23-8
------------ II -----------Edition 01.04 S00.5122.55.20
OCTAVIA
Self-Diagnosis
Self-Diagnosis
Properties of the self-diagnosis
The control unit for the diesel direct injection system is equipped with a fault memory. The fault memory is designed as a permanent memory and as a volatile memory. If malfunctions occur in the monitored sensors or components, they are stored in the fault memory with indication of the fault type. Depending on the analysis, the engine control unit distinguishes the different fault information Fault Table, page 01-8 and stores these faults until the fault memory contents is erased. Faults, which occur only occasionally (sporadically), are displayed as sporadic with the suffix SP. Possible causes of sporadic faults are e.g. a loose contact or a momentary line interruption. If a sporadic fault no longer occurs after 50 engine starts, it is automatically erased. The stored faults can be read out with the vehicle system tester V.A.G 1552 or V.A.G 1551, if necessary read out with VAS 5051 page 01-5. After the fault(s) has(have) been removed the fault memory must be erased page 01-6. Notes: The following description only relates to the vehicle system tester V.A.G 1552 using the current program card.
01
If the display of the vehicle system tester reads Information in the literature the required text is to be found in the fault table according to the fault code. The use of fault read-out scan tool V.A.G 1551 (using current program card) with integrated printer or VAS 5051 is similar. A minor deviation on the display read-out is possible.
Technical data of self-diagnosis

Interrogating control unit version The control unit version is displayed when you connect the vehicle system tester V.A.G 1552 and select the control unit for the engine electronics page 01-2.
Edition 10.03 S00.5122.54.20
------------ 01-1 -------------
01
Self-Diagnosis
OCTAVIA
Available functions when using vehicle system tester V.A.G 1552 Please refer to the table below for the requirements when you wish to select the desired functions. Function Requirement Engine off, ignition switched on 01 Interrogate control unit version yes yes1) yes no Engine idling yes yes
02 Interrogate fault memory 03 Final control diagnosis 04 Basic setting 06 End output 05 Erase fault memory 07 Code control unit
yes yes no
yes
yes yes
08 Read measured value block

1)
yes
yes
yes
yes
Only if engine does not start (starter must be operated for at least 6 s).
Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit
Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Test conditions l Battery voltage at least 11.5 V l Fuse 12 o.k. l Earth connections at gearbox and on left below battery o.k.
------------ 01-2 ------------
Edition 02.01 S00.5122.52.20
OCTAVIA
Self-Diagnosis Procedure KConnect the vehicle system tester V.A.G 1552 with the cable V.A.G 1551/3.
01
After the vehicle system tester has been connected: Depending on the function you desire, you have to: Switch on the ignition or start the engine page 01-2, table of Functions available.
If the readouts which appear in the display are not those shown in the procedure, please refer to the following notes: Notes: If Fault in data transfer! appears because of an input error, unplug cable at the fault reader, plug in again and once again carry out the steps.
Test of vehicle systems Control unit does not answer!
HELP
Test of vehicle systems Fault in communication build-up
HELP
K If one of the following messages appears in the display, carry out fault finding according to the Fault Finding Programme Diagnosis Cable: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder, or Operating Instructions of Vehicle System Tester
Test of vehicle systems K wire not switching to earth
HELP
Test of vehicle systems K wire not switching to positive
HELP Note: Operate the vehicle system tester according to the readout which appears in the display.
Test of vehicle systems Enter address word XX
HELP
K Readout in display: Press the keys 0 and 1 for the address word Engine electronics and confirm the entry with the key Q.
Edition 03.98 S00.5122.50.20
------------ 01-3 ------------
01
Self-Diagnosis
OCTAVIA
038906018.. 1.9 l R4 EDC G00SG 1816 Coding 00002 WSC 01234
K The control unit identification appears in the display, e.g.: 038906018.. 1.9 l R4 Part no. of control unit part (for current control unit version - spare parts catalogue) Engine displacement version (4 cyl. in-line engine) Injection system (Electronic Diesel Control) Engine displacement
EDC G or no display 00 MG AG
Vehicle with or without cruise control system Control unit mapping Manual gearbox Automatic gearbox
1816
Coding 00002 Coding variant of control unit WSC 01234
Data status (software version) of control unit
Workshop code from the vehicle system tester V.A.G 1552 with which the last coding was performed
List of all control units Part no. of CU1) 038906018AM 038906018GN 038906012BA 038906012CL 038906012G 038906018BR Software version 1816 2163 2830 2113 Starting date 08.98
08.98 04.99 05.99 07.00 08.00 07.03 08.03 05.99 07.00 08.00 07.03
Notes:
If the control unit version displayed does not correspond to the vehicle, replace the control unit 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System Incorrect coding of the engine control unit results in: poor driveability (jerking when changing gears, load alteration shock etc.) Increase in fuel consumption Increase in pollution
------------ 01-4 -------------
038906012HC 3316 3314

1)
For current control unit version - spare parts catalogue
4923
Storage of non-existent faults in fault memory
Edition 10.03 S00.5122.54.20
OCTAVIA
Self-Diagnosis
Functions not being performed Reduction in gearbox life
If the coding does not match the corresponding version in the vehicle: Test of vehicle systems Select function XX HELP Check coding of engine control unit 01-26, Coding engine control unit. Press key.
K Readout in display: For the remaining procedure structions.
Interrogating and erasing fault memory
Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Interrogating fault memory -
Connect vehicle system tester V.A.G 1552 and select engine electronics control unit (address word 01). The engine should be idling for this step. (Connecting vehicle system tester and selecting engine electronics control unit page 01-2).
Only if the engine does not start: Test of vehicle systems Select function XX HELP Switch the ignition on.
K Readout in display: -
Enter 02 for the function Interrogate fault memory and confirm the entry with the key Q.
X faults recognized!
K The number of stored faults or No fault recognized! appears in the display. If no fault is stored: Press key.
Test of vehicle systems Select function XX
HELP
K Readout in display: End output (function 06).
Edition 02.01 S00.5122.52.20

01
page Repair in------------ 01-5 ------------
01
Self-Diagnosis
OCTAV1A
If one or several faults are stored: Press key.
Fault number: 00542 Needle lift sender -G80 Short-circuit to earth
K Read-out of fault number on display, e.g.: Press key.
K Fault source and fault type appear in the display, e.g.: Press key.
The stored faults are displayed in sequence. Vehicle system test Select function XX HELP Press key.
K Read-out on display: End output (function 06). Rectify fault by referring to the fault table page 01-8.
Note: When carrying out test and removal and installation operations, faults, such as connectors unplugged, may also be detected by other control units. This is why, when the work is concluded, that it is necessary to interrogate and erase the fault memory on all control units. For this you must proceed as follows: Enter 00 for the address word Automatic check sequence and confirm entry with Q key. The -V.A.G 1552- sends all known address words in sequence.
Erasing fault memory Test condition l Rectifying fault Note: After fault elimination the fault memory must again as described be interrogated and subsequently erased. Whenever the fault memory is erased, it is necessary to generate a readiness code page 01-29. Connect vehicle system tester -V.A.G 1552and select the engine electronics control unit (address word 01). The engine must be running in idle. (Connect vehicle system and select engine electronics control unit page 01-2). For vehicles 08.03
------------ 01-6 -------------
Edition 01.04 S00.5122.55.20
OCTAVIA
Self-Diagnosis HELP
X faults recognized!
K The number of stored faults appears in the display.
HELP
K After the stored faults have been displayed, the following readout appears: Enter 05 for the function Erase fault memory and confirm the entry with the key Q.
Test of vehicle systems Fault memory is erased!
K Readout in display: Note:
Edition 02.01 S00.5122.52.20

01
Enter 02 for the function Interrogate fault memory and confirm the entry with the key Q. The stored faults are displayed one after the other. If the ignition is switched off between Interrogating fault memory and Erasing fault memory, the fault memory is not erased. Press key. Enter 06 for the function End output and confirm the entry with the key Q. Conduct a road test. After this, once again interrogate the fault memory. There must not be any further faults displayed.
-----------------------
01 Fault table
Notes: For vehicles 08.98 , different fault codes with the same or similar texts are displayed. The required text is to be selected in the fault table according to the fault code.
Self-Diagnosis
If the display of the vehicle system tester reads Information in the literature the required text is to be found in the fault table according to the fault code. The fault table is ordered according to the fault code on the left. Explanations concerning the types of faults (e.g. Interruption or short-circuit to earth):
Readout V.A.G 1552 old Fault number new
Possible cause of fault
00513
Engine speed sender -G28 Implausible signal
16705
No signal
16706
Bent or loose sensor washer Distance to speed sender/ sensor rotor too great Metallic swarf on engine speed sender -G28 Line interruption of screening -G28 defective -G28 defective Line interruption or shortcircuit
Poor starting Irregular engine running, misfiring Increased idling speed Glow period indicator light flashes Reduced performance No display on rev counter Engine does not start
00519
Intake manifold sender -G71 Short-circuit to positive
17563
Line interruption of screening
Line interruption/ short-circuit to earth Supply voltage
17564 17565 17566
Short-circuit to positive -G71 defective
Poor performance
Line interruption or shortcircuit to earth -G71 defective Line interruption or shortcircuit
Line interruption or shortcircuit
------------ 01-8 -------------

OCTAVIA
If components are output as faulty: First check all cables and connectors to these components as well as the earth connections according to the Current Flow Diagram. Replace the component only if this test does not reveal any fault. This applies in particular for faults that are output as sporadically occurred (SP) faults. Operating instructions for vehicle system tester
Possible effects Rectifying fault - Remove noise insulation and check sensor washer - Check engine speed sensor 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Check intake manifold pressure -G71 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Check intake system for leaks page 23-27 Edition 10.03 S00.5122.54.20
Readout on V.A.G 1552 Fault number old 00522 Coolant temperature sender -G62 Short circuit to earth -G62 faulty Cable has short circuit to earth Black exhaust when starting Engine preheater does not operate Preglowing always operates for about 20 seconds new 17663 Possible cause of fault Possible effects
- Test coolant temperature sender 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Open/short circuit to positive
17664
-G62 faulty Open circuit in wiring or cable has short circuit to positive
00527 Intake manifold temperature sender -G72 Short circuit to earth Open/short circuit to positive
17568
-G72 faulty Cable has short circuit to earth 17569 -G72 faulty Open circuit in wiring or short circuit to positive
Engine preheater does not operate
- Test intake manifold temperature sender 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Edition 02.99 S00.5122.51.20

Rectifying fault ------------ 01-9 ------------
OCTAVIA
Self-Diagnosis
01
01
Self-Diagnosis
OCTAVIA
Readout on V.A.G 1552 Fault number old 00532 Supply voltage Implausible signal as appropriate Voltage supply tml. 15 Voltage too low Voltage not present when ignition on (terminal 15) Control unit was connected when ignition on Open circuit in wiring or short circuit Engine does not start Engine stops new 18008 Possible cause of fault Possible effects
- Erase fault memory and continue checking vehicle
- Test voltage supply of diesel direct injection system control unit 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Test voltage supply of terminal 15 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Replace control unit 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Test voltage supply of diesel direct injection system control unit 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Diesel direct injection system control unit -J248 faulty Voltage supply relay terminal 30 (J322) faulty
00539 Fuel temperature sender -G81 Short circuit to earth Open/short circuit to positive
17570
-G81 faulty Cable has short circuit to earth 17571 -G81 faulty Open circuit in wiring or short circuit to positive Connector for injection pump separated
Reduced output Increased emission levels
- Test fuel temperature sender 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Several faults stored Engine stops
- Check plug connection for injection pump
------------ 01-10 ------------

Rectifying fault Edition 02.99 S00.5122.51.20
Self-Diagnosis
Readout on V.A.G 1552 Fault number old 00542 Needle lift sender -G80 Short circuit to earth -G80 faulty Open circuit in wiring or short circuit Glow indicator lamp flashes Rough engine running Reduced output Increased emission levels Fault 00550 Commencement of injection control control difference may be stored Misfiring, jerking Engine stops Misfiring new 17653 Possible cause of fault Possible effects
- Test needle lift sender 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Check fuel system
Implausible signal
17654
Fuel supply (was) interrupted: tank has run empty, feed line or filter blocked, system drawing in air (Sporadic) open circuit in wiring to fuel cut-off valve
- Check cable connection and plug connection at injection pump - Take off oil pan and inspect sender plate
Sender plate of engine speed sender bent or loose -G80 faulty
Misfiring at exactly 3000 rpm
Misfiring, jerking (particularly at high revs) Fault 01268 quantity adjuster control difference stored Irregular engine running, misfiring No throttle response after overrun Glow indicator lamp flashes Misfiring, jerking Reduced output
- Replace needle lift sender
Injection pump faulty
- Replace injection pump
Open/short circuit to positive
17655
-G80 faulty Sporadic open circuit in wiring (cable break)
- Test needle lift sender 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Edition 02.99 S00.5122.51.20

01
Rectifying fault ------------ 01-11 ------------
OCTAVIA
Readout on V.A.G 1552 Fault number old 00550 Commencement of injection control Control difference Commencement of delivery not o.k. new 17656 Possible cause of fault Possible effects
Poor performance at higher - Test and set commencerevs ment of injection 1.9-ltr./66 kW (TDI) En Engine difficult to start gine, Fuel Injection and Increased emission levels Glow Plug System
Adjustment travel of injection pump blocked (dirt, swarf)
Poor performance at higher - Test injection timing control range revs 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Engine was stalled (within the last 50 starts) Fuel feed (was) interrupted: Fault 00542 Needle lift sender implausible signal tank has run empty, feed may be stored line or filter blocked, system drawing in air Open circuit in wiring to commencement of injection valve -N108
- Erase fault memory, continue checking vehicle - Check fuel system
Engine clatters when idling - Test commencement of as commencement of injecinjection valve 1.9-ltr./66 kW (TDI) Ention constantly advanced gine, Fuel Injection and Glow Plug System Several faults may be stored - Test fuse
Commencement of injection valve -N108 worn
No constant commencement of injection possible at Basic setting (display block 2 varies over more than 10 readouts) Irregular engine running, poor performance
- Replace commencement of injection valve
------------
------------

01
Self-Diagnosis
OCTAVIA
OCTAV1A
Readout V.A.G 1552 old Fault number
Self-Diagnosis
Possible cause of fault Possible effects Rectifying fault
01
00553
Air mass meter -G70 Implausible signal
new
16485
Battery weak
The engine was stalled (within the last 50 engine starts)
- Erase fault memory, observe vehicle again Reduced performance Air mass meter constantly display in measured value block - Check battery
Sporadic line interruption (cable parting) of needle lift sender -G80
Air filter blocked Irregular engine running, Incorrect vacuum piping of Poor performance exhaust gas recirculation or mechanical exhaust gas recirculation valve constantly open Air mass meter defective Line interruption/short-circuit to earth Short-circuit to positive Supply voltage
Misfiring, jerking Possible fault 00542 needle lift sender, input open or Interruption/short-circuit to positive
- Check needle hub sender 1.9l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Check intake system - Check vacuum piping page 23-9
Poor performance, jerking Reduced performance Possible black smoke when accelerating from low engine speeds
17552 17553 17554 17958
-G70 defective Line interruption or shortcircuit to earth -G70 defective Line interruption or shortcircuit to positive
- Check air mass meter page 23-10
00575
Intake manifold pressure Control difference or Charge pressure Control difference
Line interruption or short circuit
Hoses mixed up, not fitted, blocked, leaking Pressure unit of turbocharger defective Charge pressure control solenoid valve -N75 defective
Sudden decrease of performance Reduced performance
- Check charge pressure page 23-4 - Check charge pressure hose page 23-9
Edition 01.04 S00.5122.55.20
------------ 01-13 -------------
01
Readout on V.A.G 1552 old Fault number new
Self-Diagnosis
Possible effects
00625 Speed signal implausible signal or Vehicle speed signal implausible signal
16885
00626
Vehicle speed signal 17948 signal too large 18024
Open circuit in wiring between speedometer sender -G22 and dash panel insert -G22 faulty Speedometer -G21 faulty Open circuit in wiring between dash panel insert and engine control unit
CCS not operating 1) AC not operation Possible load change jolts Speed indication not correct
- Test vehicle speed signal 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Test speedometer sender Electrical System; Repair Group 90
Glow period warning light -K29 short to positive open circuit/short 18025 to earth Short circuit to positive Open circuit in wiring Bulb faulty Glow period warning lamp not operating
Glow period warning lamp not operating
- Test glow period warning light 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Short circuit to earth 00668 El. voltage terminal 30 implausible signal Diesel direct injection system relay -J322 jamming Diesel direct injection system relay -J322 faulty
18009
Glow period warning lamp illuminated constantly
Engine does not start (safety shutoff)
00671 CCS switch -E45 undefined switch status
E45 faulty Open circuit or short circuit Cruise control system is switched off
- Test voltage supply of diesel direct injection system 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
- Test cruise control system 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
------------ 01-14 ------------

OCTAVIA
OCTAVIA
Readout on V.A.G 1552 Fault number old 00741 Brake pedal monitoring Implausible signal new -
Self-Diagnosis
Possible effects
Switch incorrectly set Open circuit in wiring -F or -F47 faulty Fuse faulty Both brake lights faulty 17762
Preglow indicator lamp flashes
Fuse or brake light faulty
- Test -F and -F47 and set 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Test fuse and brake light
00765 Modulating piston movement sender -G149
10-pin connector for injection pump separated Injection pump faulty Open circuit in wiring or short circuit 00777 Accelerator pedal position sender -G79 Signal too large Open circuit in wiring -G79 faulty (idling switch) 18039
Several faults stored Engine stops Drivability problems Engine stops
- Inspect plug connection of injection pump - Test modulating piston movement sender page 23-13
Voltage supply Implausible signal as appropriate Accelerator pedal position sender 1/2 -G79+-G185 1) Implausible signal Short circuit to positive
1)
18040 18047
Open circuit in wiring or short circuit Open circuit in wiring -G79 faulty (idling switch)
Speed governed to approx. - Test accelerator pedal position sender 1100 rpm as safety measure 1.9-ltr./66 kW (TDI) En No throttle response gine, Fuel Injection and Preglow indicator light Glow Plug System flashes Fast idling speed
Short circuit to positive -G79 faulty
Incorrect fault text readout. The correct readout is: Accelerator pedal position sender -G79
Edition 02.99 S00.5122.51.20

01
Rectifying fault -----------------------
01
Self-Diagnosis
OCTAV1A
01028
Blower relay -J323 Line interruption/short-circuit to earth Short-circuit to positive
new
Possible effects
Rectifying fault
Line interruption of Relay -J323 defective Delayed fan switch off Radiator fan constantly on Delayed fan switch off - Check radiator fan signal page 01-20, Actuator diagnosis
18020
Short-circuit to earth
Short-circuit to positive
01044
Engine control unit is wrongly coded Invalid control unit coding Glow period indicator light flashes Coding control unit page 01-26
01117
Load signal for generator tml. DF Implausible signal
17911
Line interruption or shortcircuit Generator defective Voltage regulator defective
Engine preheating not operational
Check wiring
01180 Engine/air conditioning compressor electrical connection Short-circuit to positive
- Check generator Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Short-circuit in the wiring
Reduced vehicle acceleration, when the air conditioning system is switched on
- Testing signals from/to the air conditioning system 1.9/66 kW (TDI) Engine, Fuel Injection and Glow Plug System
------------ 01-16 -------------
Edition 01.04 S00.5122.55.20
OCTAVIA
Self-Diagnosis
Possible effects
01193 Low heating capacity relay -J359 open circuit/short to earth
19460
Open circuit in wiring
Low heating capacity relay -J359 faulty Short circuit to earth
Engine preheating not operating Engine preheating constantly on
- Test cable connections Current Flow Diagrams, Electrical Fault Finding, Fitting Locations binder - Test low heating capacity relay page 01-20, Final control diagnosis
short to positive 01194 High heating capacity relay -J360 open circuit/short to earth
19459
Short circuit to positive
19462
Engine preheating not operating
Open circuit in wiring
High heating capacity relay -J360 faulty Short circuit to earth
Engine preheating not operating Engine preheating constantly on
- Test cable connections Current Flow Diagrams, Electrical Fault Finding, Fitting Locations binder - Test high heating capacity relay page 01-20, Final control diagnosis
short to positive 01237 Fuel cutoff valve -N109 malfunction (mechanical fault)
19461 17945
Engine preheating not operating
open circuit/short 17946 to earth
-N109 faulty, leaking or jamming
-N109 faulty Open circuit or short circuit to earth
Reduced output Engine stops Engine stops
- Test -N109 page 01-20, Final control diagnosis - Test cable connections Current Flow Diagrams, Electrical Fault Finding, Fitting Locations binder
Edition 01.02 S00.5122.53.20

01
Rectifying fault -----------------------
01
Self-Diagnosis
Readout on V.A.G 1552 Fault number old 01262 Charge pressure control solenoid valve -N75 Short circuit to positive Short circuit to earth Open/short circuit to earth 01265 EGR valve -N18 Short circuit to positive Open/short circuit to earth 17849 Short circuit to positive Open circuit in wiring Solenoid valve faulty No exhaust gas recirculation No exhaust gas recirculation 17955 17957 17810 Short circuit to positive Reduced output Charge pressure too low Reduced output Charge pressure too high Reduced output Charge pressure too low new 17954 Possible cause of fault Possible effects
- Test charge pressure control solenoid valve page 23-6
Short circuit to earth Open circuit in wiring Solenoid valve faulty
- Test EGR valve 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Short circuit to earth
Excessive exhaust gas recirculation Reduced output, black exhaust
01266 Glow plug relays -J52 Short circuit to positive Open/short circuit to earth
18026
Short circuit to positive 18027 Open circuit in wiring Relay faulty
Glow plug system not operating Glow plug system not operating
- Test glow plug relay -J52 Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
Glow plug system constantly on
------------
------------

OCTAVIA
OCTAVIA
Edition 02.01 S00.5122.52.20
0 1 ) ) ( 8 & % " $ ! # 8 7 7 8 7 7 7 7 7 3 ! $ ! ! 25 9 4 9 9 64 4" " 2

Self-Diagnosis
01
on V.A.G 1552 new
old
Possible
of
Possible effects
Control difference (variation) Upper stop value Lower stop value
Injection pump faulty Open circuit in wiring or short circuit Quantity adjuster incorrectly set
Jerking, poor output Black exhaust Irregular idling
Poor drivability Engine switches off Glow plug indicator light flashes
- Test quantity adjuster page 23-13 -N146 - Replace injection pump
Quantity adjuster incorrectly set
Commencement of valve
Short to positive
Open/short circuit to earth
Open circuit in wiring (fuse) Valve faulty
Engine clatters when idling - Test commencement of inas commencement of injection valve 1.9 l/66 kW (TDI) Engine, jection constantly adFuel Injection and Glow vanced Plug System Poor performance as commencement of injection constantly retarded Several faults may be stored - Test fuse - Test commencement of injection valve 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Engine clatters when idling as commencement of injection constantly advanced
Intake manifold flap valve
Open/short circuit to earth
Open circuit in wiring Intake manifold flap changeover valve faulty Short circuit to positive
Hard jolt when engine stops
Short to positive
- Test intake manifold flap changeover valve 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System
------------ 01-11 ------------
01
Self-Diagnosis
OCTAV1A
16500
Coolant temperature sender -G62 Implausible signal
new
Possible effects
Rectifying fault
Sender for coolant temperature -G62 supplies implausible signal caused by loose contact or corrosion due to humidity in the connector Signal input in engine control unit defective (control unit defective)
Cold-start difficulties at very low temperatures Poor driveability during warm-up Increase in fuel consumption Increased emission levels
- Reading measured value block, display group 007 page 01-48 - Check -G62 1.9l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Replacing engine control unit 1.9l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Check coolant regulator 1.9l/66 kW Engine, Mechanical Components; Repair Group 19; Removing and installing coolant regulator
Coolant regulator defective (thermostat)
16955
Brake light switch -F Implausible signal
17811
Exhaust gas recirculation system
Brake light defective Line interruption or shortcircuit to positive or earth between brake light switch and engine control unit Exhaust gas recirculation valve -N18- defective
Brake light does not light up Engine speed fluctuations during braking
- Check brake light switch and brake pedal switch 1.9l/66 kW TDI Engine, Fuel Injection and Glow Plug System Check exhaust gas recirculation solenoid valve page 01-20, Actuator diagnosis
Exhaust gas recirculation system not operational
Control difference
Exhaust gas recirculation potentiometer -G212- defective
Mixture adaptation not operational
- Check exhaust gas recirculation valve 1.9/ 66 kW (TDI) Engine, Mechanical Components; Repair Group 26
------------ 01-19.1 -------------
Edition 01.04 S00.5122.55.20
OCTAV1A
Self-Diagnosis
01
17931
Crash signal of airbag CU Implausible signal
new
Possible effects
Rectifying fault
Fault in airbag system
17964
Charge pressure control Regulating limit not reached
Airbag warning light comes - Check airbag on Body Work; Repair Group 01
Fault in charge pressure control -N75 defective
Incorrect driving behaviour Reduced performance
17965
Charge pressure control Regulating limit exceeded
- Check charge pressure control solenoid valve -N75 page 01-20, Actuator diagnosis - Check charge pressure control 1.9l/66 kW (TDI) Engine, Mechanical Components; Repair Group 21
Fault in charge pressure control -N75 defective
Incorrect driving behaviour Reduced performance
17977
CCS switch -E45 Implausible signal
CCS switch defective Line interruption Cruise control system not operational
- Check charge pressure control solenoid valve -N75 page 01-20, Actuator diagnosis - Check charge pressure control 1.9l/66 kW (TDI) Engine, Mechanical Components; Repair Group 21
- Check cruise control system 1.9l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System - Reading measured value block 006 page 01-43
Edition 01.04 S00.5122.55.20
------------ 01-19.2 -------------
X 3V ` Da W W 8Y ) C " 3 ( U 6 4 " " # $ $ # E 3 " 3 D 8 & ) C ( U 6 " " # E 7 A 4 ) $ # D 8 " & I I 6 Q E S R " " # # " E & " 3 I H # 0 8 " " " " # " 2 G 8 8" F " $ " "&# "" 8 " ) 8# F 40 # $1 " "F #A ! $ 0) $" $$ " 8 # & $ " # $ ## # $ $" E # $ " " 3% D" #" 7 ) C $( "7% 3 $ # " #TP# 9 ( &" ) 5 $ $ # ) 2 $& & P $ #" # $ $& % 3 "3 ' $ " " 9&@ #" $ " " 2 " ))" #$ $ $ @# 9 & 4 " " " 3 "# " " " 2 ## "# # & 6 " & % 4 qs! u q w$ v p i h d i h8 h c h d) h d" p i c h d d s s" t3 rd& b g" f r e&r3 e r b f g e) g% e
old Readout on V.A.G 1552 Fault number ------------
------------
01
of fault
Self-Diagnosis
Edition 01.02 S00.5122.53.20 W
OCTAVIA
OCTAVIA
18058
Drive train databus no message from instrument cluster 18061 Read out fault memory of ABS control unit 18062 Read out fault memory for instrument cluster 18065 AC input/output short to positive 18067 Radiator fan control1 short to positive
Datalines faulty Incorrect or faulty dash panel insert Incorrect or faulty engine control unit Fault in ABS control unit
Oil level/oil temperature sender -G266 faulty
Short circuit in cable connection
Edition 01.02 S00.5122.53.20
" !
Self-Diagnosis
01
of fault
Poor driving characteristics
- Test databus 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
No vehicle dynamic control TCS not operating EBC not operating Oil level warning light comes on
- Test ABS control unit Running Gear; Antilock Brake System
- Test oil level/oil temperature sender -G266 Current Flow Diagrams, Electrical Fault Finding, Fitting Locations binder
Reduced output
- Test air conditioning page 01-20, Final control diagnosis
Engine off fan running does not operate
- Test blower relay -J323 page 01-20, Final control diagnosis
------------
------------
4 % ) ( F & R ' F 9 % ) ( ' 6 & $ T 6 6 7 D ` &W W X V 6 D 3Y %a & " @ 9 8 & % 4 % ) ( F & R ' F 9 % ) ( ' 6 & $ T 6 6 7 D & 6 D 3 % & " @ U 9 8 & % 7 3( 4 4 & %) 2 & 6 R' ) S @ ( 6 U)& QE ( 4 & & I @ ) 7 94 4 G' "9 2 2 F ! P6 H) I 9 8 4 0 4 % 3 % $# 4 # " 1 % 0 $ 6 $ &' 0 % D$ 6 b d c &g D5 &e ( 0) ) (! % ( 7 9' ) 3#b 4 & & " & 5 & ! ( B" 0 B A $ 3 w 4 w 3 v u' t) p uf t6 t4 i$ t# pc t p v u i t p p y y#d y xp) h( se r x' q' qE x x# h r s q s q
old Readout on V.A.G 1552 Fault number ------------
------------
01
of fault
Self-Diagnosis
Edition 01.02 S00.5122.53.20
OCTAVIA
T H 9 1 i p 4 I Q & h0 T 9 9 1 '& Gg& ' 4 ' I I I ' ' G ' & 4 4 6 3(4 P f R3 FQ R 7(4 '6)() S ' I ( è)4 c4B bS@ "220))' "))0F YG A @ d2' a3 H 161 8 '7&' &X(62( ''% &'1 6 4 Q 6 )P G Q G I 422) G 04 S 4 6 (& (& U'6 P C @ # " @ ' # 225B5( Q20B) & !WQ)42( W44 0002(2# &30 9 7 (E 4 ' ( $ & )(28 0)D )&#2 0A( F&0A QC 7G" ' 2A '
old Readout on V.A.G 1552 Fault number of fault
OCTAVIA
Edition 01.02 S00.5122.53.20
Self-Diagnosis
------------
------------
01
01
Self-Diagnosis
OCTAVIA
Actuator diagnosis
Performing actuator diagnosis
With the actuator diagnosis the following parts are activated in the sequence indicated: 1. Commencement of injection valve (N108) 2. Exhaust gas recirculation valve (N18) 3. AC compressor engagement 4. Fuel shut-off valve (N109) 5. Charge pressure control solenoid valve (N75) 6. Glow plug relay (J52) 7. Glow period warning lamp (K29) 8. Low heat output relay (J359)1) 9. High heat output relay (J360)1) 10. Blower relay (J323) 11. Fault lamp2)
1) 2)
Only for vehicles with special equipment For vehicles as of 08.03.
Test preconditions for vehicles with air conditioning l Vehicle at room temperature (at least + 15C)
l Lowest temperature and highest blower speed preselected Special tools, aids and testers required
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Procedure -
Connect vehicle system tester V.A.G 1552 and select engine electronics control unit (address word 01). The engine must be running in idle page 01-2).
Vehicle system test Select function XX
HELP
K Read-out on display:
------------ 01-20 -------------
Edition 10.03 S00.5122.54.20
l Air conditioning switched on
OCTAVIA
Self-Diagnosis -
Test of vehicle systems 03 - Final control diagnosis Final control diagnosis Commencement of injection valve -N108
Final control diagnosis EGR valve -N18
Final control diagnosis AC compressor cut-off
Edition 03.98 S00.5122.50.20

01
Press keys 0 and 3 for the function Final control diagnosis. Q K Readout in display: Confirm the entry with the key Q. K Readout in display: Actuation of the valve results in a clearly audible change in the combustion noise. If no change in the combustion noise can be heard: - Test injection timing control range 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System Press the key. K Readout in display: The valve should click. Note: The clicking of the valve cannot be heard because of the engine noise and should therefore be sensed by feeling. If the valve does not click: - Test EGR valve 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System Press the key. K Readout in display: What is tested is the AC compressor cutoff. The test step is also retrieved on models without air conditioning. The AC compressor should stop within 5 seconds (visual inspection with electric torch), and then should run and stop again about every 5 seconds. If the AC compressor is not switched off: - Test AC compressor cut-off 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System
------------ 01-21 ------------
01
Self-Diagnosis Press key.
OCTAVIA
Actuator diagnosis Fuel shut-off valve -N109
K Read-out on display: The engine must stop. If the engine does not stop: Switch off ignition. Unscrew fuel shut-off valve and remove possible swarf and dirt. Repeat actuator diagnosis, if the engine still does not stop, replace fuel shut-off valve. Continue actuator diagnosis with the engine off and the ignition switched on. Press key.
Actuator diagnosis Charge pressure control solenoid valve -N75
Note:
The clicking of the relay is difficult to hear and can therefore best be felt. If the solenoid valve does not click: Actuator diagnosis Glow plug relay -J52
If the relay does not click: -
Actuator diagnosis Glow period warning lamp -K29
If the warning lamp does not flush: -
------------ 01-22 -------------

The solenoid valve must click. Check charge pressure control solenoid valpage 23-6. ve Press key. The relay valve must click. Because of the high consumption of the glow plugs, the activation and de-activation of the relays can be observed on the brightening and dimming of the interior lighting. Check glow plug relay: Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting locations. Press key. The warning lamp must flash. Check glow period warning lamp 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System.
Edition 10.03 S00.5122.54.20
OCTAVIA
Self-Diagnosis -
Actuator diagnosis Low heat output relay -J359
Actuator diagnosis High heat output relay -J360
Actuator diagnosis Blower relay -J323
Actuator diagnosis Fault lamp
HELP
K Read-out on display: -
Edition 10.03 S00.5122.54.20

Press key. The relay valve must click. If the relay does not click: Check low heat output relay: Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting locations. Press key. The relay valve must click. If the relay does not click: Check low high heat output relay: Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting locations. Press key. The relay must click (approx. every 5 seconds). Simultaneously the radiator fan -V7 must start running. If the relay does not click or the fan does not start running: Check blower radiator and radiator fan: Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting locations. Press key. The fault lamp must flash. If the fault lamp does not flash: Check fault lamp: Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting locations. Press key. Enter 06 for the function end output and confim entry with key Q. Switch off ignition.
01
------------ 01-23 -------------
01
Self-Diagnosis
OCTAVIA
Basic setting
Test conditions l Coolant temperature at least 80 C l Electrical components switched off (radiator fan must not cut in during the test) l AC switched off
Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Procedure -
Connect vehicle system tester V.A.G 1552 and select the engine electronics control unit with the address word 01. The engine should be idling for this step. (Connecting vehicle system tester and selecting engine electronics control unit page 01-2)
HELP
Press the keys 0 and 4 for the function Basic setting and confirm the entry with the key Q.
Basic setting Enter display group number XXX
HELP
Press the key 0 three times for display group 000 and confirm the entry with the key Q.
System in basic setting 1 2 3 4 5
0 9
K Readout in display: 10 (1...10 = display blocks)
------------ 01-24 ------------
Edition 03.98 S00.5122.50.20
OCTAVIA
Self-Diagnosis
01
Display group 000 at idling speed (engine warm, coolant temperature not below +80 C) This display group is used for the dynamic test of the commencement of injection. The commencement of injection valve (N108) is constantly actuated as a result of which the injection timing control is retarded.
System in basic setting 42 46 0 20 0 K Readout in display: Ignore
90
201
64
153 127
83
Commencement of injection depends on fuel temperature Specifications: 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System, dynamic test and setting of commencement of injection Idling speed: 42...45
Edition 03.98 S00.5122.50.20
------------

------------
Ignore Ignore Ignore Ignore Accelerator pedal position: 0
Fuel temperature: at approx. 40 C (is not achieved of ambient temperature low; no specification)
Coolant temperature: at approx. 90 C
01
------------
8@ 6D % 1C 79A %B ( 6 1 341 51 3") % 2 % )$ $ % ) 0 ") %( $&%" #3" 34 2 "$ 8 % 5 ""79 ) ( % $ ! "
Self-Diagnosis
OCTAVIA
If the coding displayed does not match the vehicle, or if the control unit has been replaced, it is then necessary to code the control unit as follows. and aids
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
Connect vehicle system tester V.A.G 1552 and select engine electronics control unit (address word 01). The ignition must be switched on for this step. (Connecting vehicle system tester and selecting engine electronics control unit page 01-2).
HELP
Enter 07 for the function Code control unit and confirm entry with the key Q.
Code control unit Enter code number XXXXX
Q (0-32000)
Enter the correct code number for this vehicle and confirm entry with the key Q.
fitted
fitted
00001 00002
Automatic gearbox Manual gearbox
00001
00002
00005
Manual gearbox with activated CAN bus (models fitted with ABS) Manual gearbox without CAN bus (models not fitted with ABS)
Automatic gearbox
038906018.. 1.9l R4 Coding 00002
EDC
G00SG
1816 WSC 01234
K The control unit identification appears in the display (example): Switch ignition off and on again.
Note:
The code entered is activated when the ignition is next switched on. Press key.
HELP
K Readout in display:
------------
Edition 01.02 S00.5122.53.20
OCTAV1A
Self-Diagnosis
Readiness code
Valid for vehicles 08.03
01
Reading readiness code

Function
The readiness codes are two 8-digit numerical codes which indicate the status of the emission-relevant diagnoses. If the diagnosis for a system was successfully performed (e.g. exhaust gas recirculation system), the relevant position of the numerical code is set from 1 to 0. This diagnosis is performed at regular intervals during normal driving. After repairs have been carried out to an emission-relevant system, it is recommended to generate the readiness code in order to thus ensure that the systems operate properly. If a fault is detected during diagnosis, it is then stored in the fault memory. The readiness code is erased through deletion of the fault memory, that is all relevant points will be set to 1. Generation of the readiness code means to activate the diagnostic functions such as diagnosis of fuel supply, diagnosis of other systems etc. Procedure Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3CConnect vehicle system tester -V.A.G 1552and enter address word 01 Engine electronics, switch on ignition page 01-2. Read function 08 Reading measured value block and select display group 017.
Reading measured value block 17 00000000 00000110 10000000
00000000
K Read-out on display
Edition 01.04 S00.5122.55.20
------------ 01-27 -------------
01
Self-Diagnosis
OCTAV1A
Meaning of 8-digit numerical block for readiness code in display field 2 1 2 3 4 5 6 7 1 8 0 Ignore Ignore Ignore Meaning
Ignore
Ignore
Diagnosis of other systems Diagnosis of fuel supply Ignore
Meaning of 8-digit numerical block for readiness code in display field 4 1 2 3 4 5 6 7 0 8 0 Ignore Ignore Ignore Meaning
Ignore
Ignore
Ignore
Ignore
Diagnosis of exhaust gas recirculation system If the specified values are not reached, generate readiness code page 01-29. Press key. Enter function 06 End output and switch off ignition.
------------ 01-28 -------------
Edition 01.04 S00.5122.55.20
OCTAV1A
Self-Diagnosis
01
Generating readiness code

Special tools, aids and testers required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3CTest conditions l All electrical consumers such as e.g. light and rear window heater must be switched off. l Intake air temperature below 60 C display group 007, display field 3 l Coolant temperature at least 83 C display group 007, display field 4 Procedure Connect vehicle system tester -V.A.G 1552and enter address word 01 Engine electronics, ignition switched on page 01-2.
Note: Certain steps must be carried out twice, in order to achieve the readiness code. Work step 1: X fault detected! Interrogating fault memory
Enter function 02 Interrogating fault memory and confirm entry with key Q.
K The number of stored faults or No fault detected appears in the display. If a fault is stored: Rectify fault by referring to the fault table page 01-8.
If no fault is stored: Press. Erasing fault memory Work step 2: Vehicle system test Fault memory is erased K-
Enter function 05 Erasing fault memory and confirm entry with key Q.
Note: Readiness code is erased each time the fault memory is erased. If the ignition is switched off during Interrogating fault memory and Erasing Fault memory, the fault memory is not erased. Press.
Edition 01.04 S00.5122.55.20
------------ 01-29 -------------
01
Self-Diagnosis
OCTAV1A
Work step 3: -
Switching off ignition
Wait at least 5 seconds with ignition OFF.
Note: This point is important, because with certain diagnoses the slowing down of the control unit must be ended. Otherwise readiness code cannot be generated. Work step 4: Switching on ignition
Charge pressure sender is adapted with atmospheric charge pressure sender. Work step 5: 1st test of fuel supply and other systems Reading measured value block 1 2500/rpm 4.6 mg/h 2.0 CA KStart engine. Select function Reading measured value block and display group 001. For 5 seconds increase the engine speed to 2500 rpm and then run engine at idling speed. 1st test of exhaust gas recir-
94.2 C
Work step 6: culation K-
Reading measured value block 1 1650/rpm 4.1 mg/h 4.0 CA
93.2 C
Increase engine speed to 1600 rpm up to 1700 rpm and maintain it for at least 10 seconds in this range.
In this speed range, the exhaust gas recirculation is active and the control difference is checked. (Condition for readiness code to generate exhaust gas recirculation). Work step 7: Work step 8: Switching off ignition Switching on ignition
Work step 9: 2nd test of fuel supply and other systems Reading measured value block 1 2500/rpm 4.6 mg/h 2.0 CA KStart engine. Select function Reading measured value block and display group 001. For 5 seconds increase the engine speed to 2500 rpm and then run engine at idling speed.
94.2 C
------------ 01-30 -------------
Edition 01.04 S00.5122.55.20
OCTAV1A
Self-Diagnosis Work step 10: circulation 2nd test of exhaust gas re-
01
Reading measured value block 1 1650/rpm 4.1 mg/h 2.0 CA
93.2 C
K-
Increase engine speed to 1600 rpm up to 1700 rpm and maintain it for at least 10 seconds in this range. Press C. Enter 017 for display group 017 and read readiness code.
Reading measured value block 17 00000000 00000110 10000000 00000000
K Specified value in display field 2: 00000110 Specified value in display field 4: 000000000 Press. If the specified values are not reached, repeat procedure for generating readiness code page 01-29. Interrogating fault memory
Work step 11: X fault detected!
Enter function 02 Interrogating fault memory and confirm entry with key Q.
K The number of stored faults or No fault detected appears in the display. If a fault is stored: Rectify fault by referring to the fault table page 01-8 and re-generate the readiness code page 01-29.
If no fault is stored: Reading measured value block 17 00000000 00000110 10000000 00000000 Press.
K Readiness code was successfully generated, if no fault is stored after two work sequences of the test procedure in the fault memory for the engine control unit and if the following display appears in the channel 017.
Edition 01.04 S00.5122.55.20
------------ 01-30.1 -------------
01
Self-Diagnosis
OCTAV1A
------------ 01-30.2 -------------
Edition 01.04 S00.5122.55.20
OCTAVIA
Self-Diagnosis
Measured value blocks

Reading measured value block
Test conditions l Coolant temperature at least 80 C l Electrical consumers must be disconnected (the radiator cooling fan must be off during this test) l Air conditioning switched off l No fault in fault memory
01
Special tools, aids and testers required
Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3C-. Procedure -
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 page 01-2. Engine electronics,
HELP
Enter 08 for the function Read measured value block and confirm entry with the key Q.
Reading measured value block Enter display group number XXX
HELP
Enter the desired display group number and confirm entry with the key Q.
Note:
Display group number 000 is an example to represent the sequence. Reading measured value block 1 2 3 4 5 6 Vehicle system test Select function XX 7 0 8 9 10 HELP K Read-out on display, e.g.: Press key.
Enter 06 for the function End output and confirm entry with the key Q.
Edition 10.03 S00.5122.54.20
------------ 01-31 -------------
Specified readouts for general vehicle check
Display group 000, engine idling (engine warm, coolant temperature not below +80 C) for models 04.99
Read measured value block 42 50 0 20 90 0 K Readout in display
Injected quantity: 11...45 o.k. if not to tolerance page 01-36, display group 001 Accelerator pedal position: 0 Commencement of injection: 12...75 o.k. if not to tolerance page 01-39, display group 004 Idling speed: 42...45 o.k. if not to tolerance page 01-42, display group 002
1)
The measured values apply when the exhaust gas recirculation is switched on. The exhaust gas recirculation is switched off in the idling speed range after about 2 minutes; if necessary, briefly blip throttle or re-start engine.
------------ 01-32 ------------

201 64 153 127 83 Inducted air mass1): 69...111 o.k. if not to tolerance page 01-47, display group 003 Fuel temperature: 91...201 Intake manifold temperature: 182...50 Coolant temperature: 80...35 o.k. > 80: warm up engine Ambient air pressure: ignore Charge pressure: ignore Edition 02.01 S00.5122.52.20
01
Self-Diagnosis
OCTAVIA
OCTAVIA
Read measured value block 42 50 0 20 90 0 K Readout in display
Injected quantity: 15...45 o.k. if not to tolerance page 01-37, display group 001 Accelerator pedal position: 0 Commencement of injection: 12...75 o.k. if not to tolerance page 01-39, display group 004 Idling speed: 43...46 o.k. if not to tolerance page 01-42, display group 002
1)
The measured values apply when the exhaust gas recirculation is switched on. The exhaust gas recirculation is switched off in the idling speed range after about 2 minutes; if necessary, briefly blip throttle or re-start engine.
Edition 02.01 S00.5122.52.20

Self-Diagnosis
01
201
64
153 127
83
Inducted air mass1): 69...110 o.k. if not to tolerance page 01-47, display group 003
Fuel temperature: 91...201
Intake manifold temperature: 190...80
Coolant temperature: 80...35 o.k. > 80: warm up engine
Ambient air pressure: ignore
Charge pressure: ignore
------------ 01-33 ------------
e e U T T T f I W T T C P P @ F e Q T W P eE hT g y QI@ Q VV fU IsS` VD fD è TU If T9 fB VW iQ iI CT SqSE 9U DE tx HP a Q y Q `V I V bI 9 eB Qf `tT fu iQ T f V C 99 9e DC E 9 D Q ` T G 9 r 9 e Q `9 T T W E B B ba F @ 9 I f I T Y @ U e Q `s` T V T i I V ` CB Fa bT D @ u UF U eI aaf aST aST Qi `` TV V TS TT iP I V T V C9 SC D9 baC BI @` 9T Uq` eqa aia aD ag Q9 Q TR V TT i `T Ta bXy 9T Df Be 9x rqP pa ev cH eCe hr gT QaDX XI Xi TT fsR VaST èa fT ibP CT CI CSiT DI 9TtaX DPqg 9aT Dae B@ BiE USI aB aWa XI `r VV Waa9 WW TSSi IS Ri Yy CaV CaSti bD BI PhT PR CXttatss CR CiqS GI C C BhXXX 9W @qqA FSwa 9t Ess Aa 9 D B A @ 9 B Sf 6Ss # # H ) ' 3 5SSw %` !hq@ aaH B sa) u &T90 Tsi( PA0 "XSX1 aaa C #4 $T) BXq bs0 IB 7 7 9 Qai2 ) @ W
Read measured value block
------------
01
Notes:
The measured values must be read off or printed out (second person required) once an engine speed of 3000 rpm has been reached.
Accelerate the vehicle at full throttle for the test.
group 000 at full
-----------
not to tolerance
Accelerator
not to tolerance
Ambient air
load injected injected quantity system
test in
display
warm up
Self-Diagnosis
or
K Readout in display
on
gear,
display
air
detected
display
not
+80 C, engine
Edition 02.01 S00.5122.52.20
OCTAVIA
memory
OCTAVIA
Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not below +80 C, engine speed 2900...3100 rpm) for models 05.99 Notes: Accelerate the vehicle at full throttle for the test.
Read measured value block 186 225 255 186 186 201 64 138 175 255 0 K Readout in display
Charge pressure: 179...215 o.k. if not to tolerance page 01-55, display group 011
Injected quantity: 199...214 (full throttle injected quantity) o.k. 125: emergency injected quantity, system fault detected page 01-5, Interrogating fault memory Accelerator pedal: 255 (fully depressed) Commencement of injection: 137...215 (depending on engine speed) if not to tolerance page 01-41, display group 004 Engine speed: 134...153
Edition 02.01 S00.5122.52.20

Self-Diagnosis
01
Inducted air mass: > 255 o.k. < 255: page 01-53, display group 010
Fuel temperature: 91...201 o.k.
Intake manifold temperature: 190...35 o.k.
Coolant temperature: 80...35 o.k. > 80: warm up engine
Ambient air pressure: 183...224 o.k.
------------ 01-35 ------------
Specified readouts for injection pump
Read measured value block 900 rpm 5.6 mg/s 1 K Readout in display
1.480 V
Engine speed Models 04.99 = 875...950 rpm o.k. Models 05.99 = 861...945 rpm o.k.
Injected quantity 2.2...9.0 mg/s: o.k. < 2.2 mg/s: - Injection pump damaged replace injection pump > 9.0 mg/s: switch off consumers - Engine load - Engine too cold warm up engine - Injection pump damaged replace injection pump
Voltage of modulating piston movement sender -G149 1.450...1.950 V: o.k. < 1.450 V: replace injection pump - Injection pump damaged > 1.950 V: - Engine load switch off consumers - Engine too cold warm up engine - Injection pump damaged replace injection pump
------------ 01-36 ------------

87.3 C Coolant temperature 80...110 C o.k., < 80 C: warm up engine Edition 02.01 S00.5122.52.20
01
Self-Diagnosis
OCTAVIA
OCTAVIA
Read measured value block 900 rpm 5.6 mg/s V 1 C K Readout in display
Edition 02.01 S00.5122.52.20
$ ! $ " # ' ) ' 0 % $ # !! "# # 3 5 ! 2 1 ! $ $ !! "& # & ' & )" ' ! ( " 0" % & $7 $ #( !6 "& " # ! #4 # ## # ## $# !" # ' " " "# #"##
Self-Diagnosis
01
Voltage of modulating piston movement sender V: o.k. < 1.30 V: pump damaged replace pump V: load off consumers too cold warm up engine pump damaged replace pump
Coolant temperature 10 C o.k., <
C:
warm up engine
speed
3.0...9.0 mg/s: o.k. < 3.0 mg/s: pump damaged replace 9.0 mg/s: load off consumers too cold warm up engine pump damaged replace page display group 001
pump
pump
------------
------------
F C F X @ H 0 Q Q a H E 8 F E C c P FC CH H1 FpF XE @GC HP EE d 0@ 02 Qb6Gc QR86 aHE H)Y EdE 88F FSF E8 `R6 CC c0Q 5 GX GC PEX `FRS HB G8RbG G C S4 g)RHbGG f6bXIS X St Q5 Q63D Q CGG%fG HGH33 6R6 8C FRISH HH 8p1 CGH 6u ERE 8Y 8P EC F1 H GF G4 xF1 uQc PF IGbbB IIwG1 IC @1 Hf3 63 C3 F tU3 1C QQGD aC EP 5RDI FG E GE IH 3C f QF 5t 5cS d8 d 8 Hc Em EH X4 ` Y PXS eRF P QHE QE Q a FF6 5GbGG FHRbG CH HQ FC XF HRE EC H FR F X ` H H X H GGvI GX edl PC R6H XG pf 3CcD C33 Q a1 CRQ333 FebG1 E13 `R Hd HC FE HE XQ XF 8G H GG` GGE Yf3 PE PP h ) Rd IR2 bW g @ QDb Q a HGGDID E 8X F cC PRG 3I Q QG f 5ba 5 6VH FH HQ FRE dH X dP H 6 E C YH e RU QH Q 5FS Fk CE dG6GR 6RbVSGps FR1I 8P ERGr CP CQ 6 FGI 6 H cf c PH eEDG Pd RD` D1 I33X @F SH SFE QHRVG1 adRIR Q Ed6 FCDF E3GciRc `dy CEbG6 5 C C E C EHR1 H)R4 HGCb9 X8 6 F E G88 GQ1 PH81 T1 UQG 4GF RICGj W6b PEGRGRS Yt VE I@ F ERfGD2 C@ C GRcGG DGDR BSbI33 @0 3h 5 8 2 4 B 0D 4h 1 9 AI ) 0 6R " GRH !3 d7 F "7 R "i "bG s d pc GF D3 %3cRb &1 $1 G #) 3 '2 (RH
Read measured value block Read measured value block
------------
01
the vehicle electrical interrupts the
rpm
group
------------
V Not to
Quantity
ignition
speed
resistance in cable connection pump incorrectly set
V Not to
Quantity
est
piston movement sender at minimum stop
drops below
resistance in cable connection pump incorrectly set
rises in time or constant system memory supply control
on
No readout
piston movement sender to control unit position rises in time V closed display block only pump
piston movement sender at maximum stop
Self-Diagnosis
No readout
temperature
the attempt at
replace
is
replace
pump
in
the vehicle system tester V
pump by control
pump
valve
replace
Edition 02.01 S00.5122.52.20
OCTAVIA
V p IF X V7 SC pw qfw C A C fI C x XA AD Cy VA SRPG A6 CA GA Ft F A A C HS 6 P 06 Yh 0r7 eS I XG fP SS pI FA sHA CA A0 pS F0 qS qp FfS V AH V V F C S S A G C tA iA ha D V p S A y F F 7 6 4 5 c 5 Is Xt I V5 SA p4 qC CC A5 C8 S A S G S p A Hp Pp A G x h y w a A G X8 X2 w Xp VfS VPW FA FS AS G5 Ss S S v S A 6C f6 PA 06 YGC 0X rS ePSRQ I0 y SAF pXc FAs s7 C7 AC pC FPGPG qPA qS FA V AHG V V FQ C A A S G tAPS iS h` PAH 7 PGH fS Pf2 b Afw CS St Ay CfP8 GH3 A F F HS c DuA PHW3 RD PuS 7 6 ` 5 Y 1 7 6 7 4 6 5 aR 5 8 X AWW V CDEB SHue AfPA Cde GrPy F A S C U P3e RHu3 0e 1 9PW 8H E1RH IS ArPH11 CHD FF FD1e A6 Cfp SRT11 A` CSH GGDS Ct Ad H5p H HEH @B D4 PFDH PCA QRi DF Pf BA 0 0 9P 7 6 4 7 6 5 4 2 ) #8e A13 81 H3HfRPfPW R3D1 "111Pu S !5 R dWP DPPWPR W P3 P2 e 3 Y $CPWP 'ffSPPfP CDH1 %Au &YH1 (y af 1
engine idling
speed too cold commencement display and set too cold commencement o commencement valve pump stops too late and set valve pump stops too soon
Display group
OCTAVIA
Edition 02.01 S00.5122.52.20 900 rpm
Self-Diagnosis
up
ratio
requested by control unit
up
not
commencement
and
and
control test commencement
blocked control test commencement
------------
valve
------------
01
f p ` X Xp `gf pgX XX `` dp `G c X eX S f ` GX yaR f X d ` pid cX p `X XgS X caF p ca Xe c ES Hd` Ep t vp gr a X p p X p X d ` ` c ` d t X ` p X ` d e H p c X p G fe` p fR R p ` d `T Xi `d p XvgP pe dX p X eX ep T f gX S b v` F vF t iQ h vp Xp àX pgp Xp `vF dX ` d es gw` gp S G c E H E vc X f Xgeh `gi pt X dgg X p p ``g Xpgp cagB `gx Xyd cd Xc c e e i pe d gXe T g gr v` uI x ` ` pt XwgI cIvI wE q I ` sgE ViwI EP bay fU XdvgE `pgH àeD Xgep `vIew cp dIX XXgG `vG ppE dtyeI Xa eu e aa`g g` aaX WyI gvpgay iìr hiebe g` ay BI G VigE TggIg SI Q Ua S R H P P BII YvD $ $ 2 7 9 dIawg4 &` eQ !èI6 'dGI p4 X a $8 %X pgeF T 3 A #gi!H ev h aYvb "y5 A (pIav@E 1XIY )cR4 0d re D G I
Read measured value block rpm
------------
01
Notes:
group
-----------
at full
speed
rpm
commencement
and set
test in
in
to
too cold
valve supply supply pump stops too soon
Self-Diagnosis
commencement commencement then
or
to
ratio
warm up
gear
requested by control unit
test
commencement
commencement
and
in display block
control leaks test commencement
valve
not
and set and
control
valve
Edition 02.01 S00.5122.52.20
OCTAVIA
engine
OCTAVIA
Display group engine speed Notes:
Read measured value block rpm K Readout in display ratio
Edition 02.01 S00.5122.52.20
X r qW b v w R P R D 9 PYX RV bD PP RP VP Rg8 P WC E R b y 9P pSb X bab vX Ub yX Rw PR vYP USgX wYP wb US q PW q U P V R 7E @b 7xb u te Yd S q P b U b v P b P V R R P U b V e PgB b P R b y V W @w RY P R U P b v XWV ru Xr qP bt vP wrV RF Pb Rb b8 Px bb Vb bw vS WP WV F Vh E tT D gR 8 g8 d e ab ` Pb RSP q bYb Pr RR VP R P V Wc YhR a YP E v U y 7 @ 7 xq rgU Xb q q q PWb RS4 bw PYaA R` VYYW P b b b Rq PbWW v Ubga wRSY wPe UP PU U R Wu W Y ah ub tE YPW F Yv gP Yb gR fp iR R6 RgA bAA U7 bgYV h cA c Ai R Ha9 7SY ThW XG PVWhA RbY@ RSb PxYA7 RWWP UWad Ve Pb7 Rg9 bb7 VeSYb PW Wf Wy SSR YRB SSTP IWA YVYSp aRv àu Sp Sp 9 9 9 HaYAYYAY FA EA C GA F E D D B 4A QgS 3 ) ( UÀ A #dhY20 YWC g0 9 !6 A 4 R Y p W1 @ YSY8 Y p@ R7 g $9h0 'PQ %PQ "7 &VAp VATB YgW W AYg6
Self-Diagnosis or gear
01
at full
for
test in
05.99
not
commencement valve
valve
to
control
test
commencement
commencement commencement up
and set and
in display block
to
too cold
in
and set
valve control supply supply leaks pump stops too soon ynamic test commencement by control unit and
commencement
speed
rpm
------------
------------
01
Specified readouts for engine idling

group engine idling
------------
I R R Q C S C I b I C @ b I S b C @ R R B C b @ 9 a 9 R B V 5 2C 2b 5 2 R @D S V t Ih R RvS RS R@ d@ e db QY S C @ CrB @ CC bb C C w yh xC i q u t A f E T p r 2 c 2 d eI BR DS 4 ` @ 4T E R @P B RSP 1C 5 2PTP RC SC CI`T BVD VC` @5 @@ SB BPTD V Pa S CE D`R YbTT UTA TB T 7 Ib` RGD RXR F 2C 6 G QBTDT CRD`` SI Ct B PR 9S 8X 2 5b 5C 2 6 32 32 3sDTT 3 @CTTT` 9a ETr 8@ Cb BAR @s @S D@3 ATTA 9D 63Tp 6`G 53 2 2 95 4TT 75 8 1DDTATA W !b3 !P C 5 S D 3TT %3 AST3 #@ h & "D )DPA ARG 'SA $TW3 (d33 0V g
Self-Diagnosis
OCTAVIA
coolant t
not
Read measured value block 900 rpm
K Readout in display temperature
pedal position
state
able
up
states
speed
accelerator pedal position sender incorrectly set or and display
of engine operating state

if positions = 1
state
speed air
speed
on air accelerator and brake detected test brake pedal coolant additional eater up
on
------------
Edition 02.01 S00.5122.52.20
r r e e e r f r r e e r e s e e e e e e s w w r e e e e e s r r r e e e h q rt rp e r e e f g s rh rp ep ep ev d ep s W Xw q X I F X Ru Vq Hq W h p ig p i f q q xF U p x j r ii ete sr R qIr Up yq wiv uir tHr Xe pei p egixxxq sih qpF vr qXG p q G V R V rv eiiw Yw X G a ir iI pxxe bpe `xb GiHiUX XY x` cG a FR Gqe ù G dHQ U qt rh xt s qF dG E u dh Hf H W X F G F I G R 3P CHH 3 A 9 3 0&U 3v 0v 6u )V %(U w 13 43 'R %S Q 6 2D &3 3g2s 0y )8 5 1r 4w 'q %0 ` "7 "U #t G (i(t &7u 3e 0c )xgXig 1G 'qi 'r %f f "! "B #E 2i U ig ! e T@ xg8gP iHH 2H
Edition 02.01 S00.5122.52.20 Read measured value block
Display group
OCTAVIA
Display 2
operating unit of
ignition
pedal
ignore
and
pedal and brake pedal depressed
pedal and brake pedal not depressed
pedal depressed pedal
pedal depressed
pedal monitor
pedal depressed
on
pedal
operating state
page
Self-Diagnosis
operating state
page
Cruise
operating point
pedal depressed
pedal depressed
pedal monitor
page
operated
to
rake pedal
display positions = 1
pedal s
ocked
Display
closed
------------
opened
opened
------------
01
01
------------
# ! " # ! "

Self-Diagnosis state
0 1 Model with CCS - CCS switched off
OCTAVIA
state
2 5 5
Model without CCS, CCS function may not be activated in engine control unit
Model with CCS - CCS switched on
------------
Edition 02.01 S00.5122.52.20
h ja {g x x h p |l x l9 |p xj hr rC l jI { l r iirn i wl zz zu yfifn fl wq wd ~ ld j m nu xj5 lu phf jygn lj ol ll hr jx x xgh { lw h |x mxr xg x9 mz |i lm j i i|yo ij i s z w fhl wH zl ym fi& 3 3 #t @D h @ ! 5 ! F# )6 5 4j " @ 3 ! 6 F# )# 5 6 #" 5 9 &3 99 9 g @5 !$" 3 !5 3 D 6 6 r v b 3 H 9 a ! p @gj !c l 9 ! 3 6 b Cl g X 9h a b 0Ye $i 9 #} Y 8 l @j w l m G vj 3gz U 4R r !h t 66 C6o 9p h l @Q z yo l l 3p g6 g~ l !r k 6 &r gj &u 9 iI %t"R j yV iYT 6l wlmP bSSS vigt ck x6v bW blm x v6j bj dj c~ bI rl cm uig| p#m tm iH tm pI pl eii gmifid fgmif digi ciege bgii amgg X I X W U " ! 6 3 C 9 E ("6 & F Br 6 @Bs 3 q6 ! 6 3e 6 5 Cp &3 E )D (qBh 8 9 v 6 2h # 7 Y ! 3s 3d 8 %# 2 "5 6 3 5"q4" Bh sh 6"e !e6 !` 6 I %6 1 " " Q %h 0 ' )H (R & & & & & & $ $ & #"h T V !4 &6 DG 66"6 & 5h R "" 647 h S % P
Edition 02.01 S00.5122.52.20 x x Read measured value block
Meaning of the digits in the 8-digit numerical block for additional heater:
Display group
OCTAVIA
Meaning of the digits in the 2-digit numerical block for actuating the heating elements:
able
able
additional
engine idling
load
Actuation of heating elements
of
if display readouts
or
05.99
elements
if display readouts
less
Self-Diagnosis
able
less less
or
off
able
------------
------------
01
01
Self-Diagnosis
OCTAVIA
Display group 013, engine idling (engine warm, coolant temperature not less than +80 C) The fuel injection system features a smooth idling speed control. It is possible to detect performance differences between the individual cylinders (parts tolerances, injector flow, compression, etc.) and to compensate for this in the idling speed range by selective metering of the quantity of fuel injected.
Performance differences are detected in the idling speed range from the signal supplied by the engine speed sender, which supplies four signals for each crankshaft revolution to the control unit. If the signals are received in the same rhythm, all the cylinders are performing the same work. If one cylinder is weaker in performance, the crankshaft requires a longer time for the next half revolution. Conversely, a more powerful cylinder accelerates the crankshaft to such an extent that it requires a shorter time. If the control unit has detected a variation, the relevant cylinder is immediately supplied with a greater or smaller injected quantity until the engine is again running smoothly.
- ... mg/s: The relevant cylinder is stronger in performance and is therefore supplied with less fuel.
+... mg/s: The relevant cylinder is weaker in performance and is therefore supplied with more fuel.
Read measured value block 0.82 mg/s -0.12 mg/s
0.49 mg/s
-0.12 mg/s
13
Smooth running controller - injected quantity cylinder 1 -2.0 mg/s...+2.0 mg/s o.k. > + 2.0 mg/s: cylinder 1 weak < -2.0 mg/s: cylinder 1 strong
------------ 01-46 ------------
Edition 02.01 S00.5122.52.20
OCTAVIA
Self-Diagnosis
01
Specified readouts for exhaust gas recirculation
Display group 003, engine idling (engine warm, coolant temperature not less than +80 C)
Read measured value block 900 rpm 290 mg/s 3 K Readout in display
Engine speed
Specified air mass requested by control unit 230...370 mg/s o.k. > 370 mg/s: warm up engine - Engine too cold - Injected quantity too high specified readouts for injection pump - Intake manifold temperature very high no correction possible page 01-36, display group 001
Edition 02.01 S00.5122.52.20

308 mg/s 54 % Inducted air mass 230...370 mg/s o.k., must agree with display block 2 within tolerance of 20 mg/s < 230 mg/s: inspect intake system for leaks - Unmetered air in intake area - Excess of exhaust gas recirculation test 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System > 370 mg/s: - Engine too cold warm up engine engine idling for 2 minutes, - Insufficient exhaust gas recirculation briefly blip throttle - Air mass meter faulty test, page 23-10 Constant 550 mg/s: substitute value page 01-5, Interrogate fault memory On/off ratio (actuation) of exhaust gas recirculation valve 40...75 % o.k. -----------------------
01
Notes:
Once engine has cooled down, the temperature readouts of fuel, intake manifold and coolant must automatically be approximately the same as the ambient temperature. If one of the readout differs noticeably, test the appropriate sender.
It is not possible to state specifications for the temperatures.
------------
E U ` E t G s @ 9A TI g H Q g P Ut VP rB Wu ` pH iI` gah hr hYaSH PSp HRW eQ eR Pc fdh caab Qd b RC YQ IbP T@ PT Q P H H E UcIB VQp GDq WPR 9 A E E G @ F D E D 9 1 $I$ 1aX@ 1R "h 1XI '3 &S 1 1 4 %" 7DYA 1Q &P &Y& &aTb 4X( 6av $ 1 1 4 1 & 1 ' 2d ) 5@ 5$ 5B2 8& !Y# ( Y! Y C aaX R% D B0IB
Self-Diagnosis
OCTAVIA
readouts for
senders
temperature open circuit in
readout
temperature intake open circuit in constant
temperature coolant temperature sender open circuit in temperature is displayed as substitute value
temperature sender is displayed as substitute value
temperature sender constant is displayed as substitute value
------------
Edition 02.01 S00.5122.52.20
OCTAVIA
Specified readouts for

speed group
Notes:
t w ` i a c x e d i e i Vg W W Yc Y i i ` xt a c x u X b hW tU aYc gR gw ` i g c vp X ` U U R T ` i g i gf xr u ia i pp xp pg ug cp ii x aq rqf V V Ru Wr Rs Yi Yi tr w it sqt id gq aw ivT ` ì ag cgu xu i XU Vw T bif vq ia tfg w tu `q iY` ag cYcX xv gfr xvi ihY gv iW pU iU gq au ga qYu qg ex dvx j vi V d i g a u av ct i x f ub ci i c p qvw g s iqt axU uct qvvx gc ix gs pqr i i p qx UWyf dtp Tyc Xgq Yvg r yg yvx vq W p ` aq cY df bp W W Yd Yq Y qi `hqg xYY aYY cvv TbY dv bp tfY wi xi g uY sf iv ia gf pg qV qX qy y v Wb W `q ` cf a c c eb dy X RYv Yq % % 5 5 8 4 ! ) Q Q I %yycfvF 7i 0hW ' % 3(q 3W 9vUh 81a% 4)q# 5Hvq 6sqf 4aYV !ihb #cY 4T 4fyY& ( @` 1b BtX &2a A(t! "rqD YU '" hb% % C PU T "bE GE E f( Y Y $
Self-Diagnosis
01
at full throttle (road test in for
or
gear coolant t
not
engine
Read measured value block rpm K Readout in display
limit because
detected air mass
air mass
limit because
est air mass meter recirculation test and speed
at
speed too pedal
or too
increase by
set or
pedal not test
accelerator pedal position sender and
incorrectly
speed
rpm
Edition 02.01 S00.5122.52.20
------------
------------
V Y B Q C E ` v GQ q 8I 9 A B `V C4 E9 ` Q Q dW bE @ D V7 CQ IAS IY B Q I E XV @ B 7 7 6 4 U B I Q IT `XwR WASR QQ qQ RQ `R RI W7 ER Qi ` C8 TSY tp @ 4fQ 9T 4Y AQ AI VT Y QV UE Q IS CU QQ Bt BW CIb EIW `q @wC @U 6g DQW X` XuC x7 VI Yq VE Bix QAuB CIS EAX` `XQ IHT `XQ QPAw IpuI Q9 RV Qd I7 CS Id SAE@ SC r `H W v g y rXX6 b ub d F xQ ue I W7 EY Q E R s WC CXub EV ` sI r tD a fg Q QSVR C`d WEV qSy IQ QXST IF RSXQ Q Q Q R Su` 79X` FVR 6xaE @pIS iAXI T aW XSe e 9 BuQ C ER @ 9 9 AF A cXw BPuSAD `fuA CcuA EAI DR bDX @XI VA YQ `QD Ir WA UpH Qx QC Iw Ra S8 S@ a Xf 9Xf BSuA B Euu E GSA Fa @ 4cSX ASA ' ' ( 3 2 aCS "SWA8 uPDP aH tcSS 9 #dX7D0 aEHX1 89 H À !UA7 CAPD E 67 ASS9 S @ C E a $B0 &VDAP QSX0 % TC cA) DH6
Read measured value block rpm ------------
------------
01
Display group
Notes:
at full
speed
set or
(road test in 05.99
rpm
pedal not test
at
Self-Diagnosis
or
limit because
speed too
gear
pedal
air mass
accelerator pedal position sender
and
limit because
increase by
or too
est air mass meter recirculation test and
speed
detected air mass
not
incorrectly
Edition 02.01 S00.5122.52.20
OCTAVIA
engine
OCTAVIA
Notes:
I W B UE UX R S C BS Sq cpS IE Rd SQQ CVA C EQ WS IC X f gdV pS TS eYb ir VXT PIA YU SRD BQPi WXb SU EC XXG SRT IhVIW WsVC CVb XQS CT WVS TR H @ @ B B E E F F 9aD G HV5 9 5 @ ( #TWV $VWQ I S )CYQD WA $W c! )WV7 U QPW S ` %c #Q Xb9 S t E u y 0RIa F C 8 X 3QVUAw CCY 1'S &%x 2&GV 4SR Q Q " `v
Self-Diagnosis
01
1)
Read measured value block rpm K Readout in display of
limit by automatic
piston movement
control system
available at
Edition 02.01 S00.5122.52.20
------------
------------
8 e S BF B C Q B C C E B I V 9B B F B C E C ` ` D B ` B E E 9 9 U D I E Y E e F S Q P B Y U 8D 8B 8 F ec F S F F SC B C Q E I E B QQ EC B C Qu PY `Y VP 9I 9B DB B I E 8 bC b F ExE Q P B C E V cP 9 9R 9G D 8 GV FRC9 SC FS E I CP uGw BGP 9S PBf IB EY BHE I B YC BY II aB GE9 GC gCT Dc RU Q 9Q s vB P yB r i wY H x` BB PD F SIB SCG C`Qd BFGI BfHRP PU`H EBb IHI YBRt YbC BE IQ BC IX EwF Pb QfB PE B` QqB EB BP BP Y` Y `RGI hRQ GE GBG g i fCP RG8e RrRRB DY D` X RGD F9 Sc BQ BR QB B P`F PSI E IE CGB BGI E` CQ BB BB Y9 `B DB DE DÌ XP R9 R9 d` 8P aG WC 99 89G bCH bD aY EEGa E`G CP BC YE YD `C IGÌ E`B E` QT C PP BC QV GF cBG` XG WGRG 9GPbR 9ty DX H`P HF R 8 V WGaaHH 9HHb` 9bG A 8è SReCe FGabRHGGHG He` CHCqq Q8f` P`fF ETG CPe B`Y IE` GB DGReeHHGG D8e 9G` HY` HB ' 1 7`G 7U 5Hw $ RH``` 6 f) bÙ `BRGG P !eB$ `P9 `( `G$ 4 B$ Y9 89 I fHB2 QG` Ba3 ' "Bb`0 &C9H0 $Q`GH0 #BP %TQ 9` R T
Read measured value block mg/s ----------- mass mbar oo l mbar or
------------
01
Notes:
Display group 010 at full
mass mass value
mg/s
test in
Self-Diagnosis
or
s block
gear coolant
mbar
not
Edition 02.01 S00.5122.52.20 or
OCTAVIA
engine
C p X GQ G H V G H H P G a DG G G Q G H P H e e I U G V G G P D D ` I T P d P d p Q X V G U G d ` CG C C d ph Q XH Q X Q VV PH T HG VU UH G H V ed P T P G a aQ DG IG DP G T P C g Q Pd V U H P a hP D Y DfWI DW R C eY QWHD XP QX PI T HU U GRG DX UGH TT Pd G TP G dH GT Te T RPq RH rH Ih W` V De xI G U U w S W GG Uq p Q XTG XHG Heti GQRT GU U`We PGR TSgXSWU dGWy dgH GP TV GH TeG PQ Ug VP UeU GRWG VvWH PG GG GU dD eG sWV RP RGR r tRS qHRI WRCp WwV Id IeT c Wqe QS Xh GV GD VRG G USeQ UP Pd TD HRRT GRT HV GG G dU RP Id IP IeP cT Wd WU ie Ce fg bH DD CDe gHSR gI fD PQ PeRR HU GH dT dI ea TCq PRV PeG VRG H UG GH Va RQ hGWSRR cpf bGe DeP Dy Ic SU W C a bRfWfSS DSSge DgW ` F Ce XpHp QRfU SpSSRp HSWHvv VCe UeqgRgWe PYSR HUR Ged TPe RG IRURR ICp DRRp Sde SY # # S ) 3 @ BR B %G !e) e R Wc 2eGWRRe &pG eUD e5 "SQ G e) eW` #gee4 $GS dD Ce Tf8 qS9 eR7 G 'Pge 1HDS5 )VeR) (GU5 0VRD DqA 6 Y
Edition 02.01 S00.5122.52.20 mg/s
OCTAVIA
Notes:
group 010 at full
mass
mbar
mbar
or
mass mass value
mg/s
test in
Self-Diagnosis
or
s block
gear,
mbar
not
------------
or
engine
------------
01
01
Notes:
Read measured value block rpm mbar K Readout in display f ratio (actuation) of
------------
` h` w v t s p t s t w r w f r wrr va tt uY vW p t h jw ss sW k wpW vw tv ud wh v l td uob t u` d av Yw fw rv w w w wt ph hv h s g e r d w w w v t w u u u xw w v` td ` Y w v p u aw Yp y s r u w v t h w w u Wwu y c ` w v tu p u hm d n `h` `ju sp t sw s ` s ` ` b w v t w p s pr dw diq fu qv a xwr ru ww vW tv uw ph hx dw c yvW gx sh iu e f b b W W x 8 8 0 1 0 # " 3 R V' T$ Sq @ua 41 'rY 2" 5W 5w'G Avu) 8) 0'H 133 9tD 1w$ #" %h# 1V1 7ux' 1r& 0)' 0ub %( 6uP )r` 0 1 BwU% $xq) Fs` Dxs# C(W E)'uuD $d u` c! 2 I$ ` QI I D D
Self-Diagnosis
OCTAVIA
readouts for
pressure
group 011 at full
(road test in
or
gear
not
engine
mbar
pressure control solenoid valve tolerance of
icient
pressure must
display block
mbar
pressure control of c
valve
at
pressure control dropped off or est rusted pressure unit faulty
solenoid
est
speed
pressure by control unit mbar mbar pressure increase by rpm
------------
Edition 02.01 S00.5122.52.20
OCTAVIA
speed
Notes:
A b c IA X W fA E A X U T U t S SVc W u WS XVt WX U@ V U f8 u TX YU Sc uA XD Wh UQ v XS XW vU XC tX WT tX Ut e e BX @A hB E TfY X SVQ iE u XW QT U X X t W c T t y S u X v X W t U X t V V V T YX Xt Wfb vV tq@ X Q fV BX @Q hv ` T S uV u wX XV v X tV t U I Vy t 8Xv rXf ph p8 IT X8 Xh WV Ua Q V fv E E f AIqA AuE TQ hU TqX A qT c h A C g XR Wa e X Q d Ta aaV a a QS EX EI GV bW BY YTS SVaa Xib W8 UW Qa If VX EUS DÌ HY PY `W8 Tt Fa 8 Gaq Ca A C C 8a 8a Ra " " 7 3R 3 ( ( 5 $WVA ( q q u 1XVB %UV( iqUa3 c !V S VA aR6 "t4@ #U( X iwVa I2 Iq SA &Xii4 0Wqs4 (Iq84 'f )WVa E YD
Self-Diagnosis or
01
group 011 at full for
test in
gear,
not
engine
Read measured value block rpm mbar K Readout in display f ratio (actuation) of
mbar
pressure control solenoid valve tolerance of
icient
pressure must
display block
mbar
pressure control of
solenoid valve at
pressure control dropped off or est rusted pressure unit faulty
est
speed
pressure by control unit mbar mbar pressure increase by rpm
Edition 02.01 S00.5122.52.20
------------
------------
OCTAVIA
Fuel Formation / Fuel Injection
Servicing diesel direct injection system

Safety precautions
Pay attention to the following points to avoid injuries to persons and/or damage to the fuel injection and glow plug system: Do not disconnect and connect lines or cables of the glow plug and fuel injection system - also not cables of test equipment unless the ignition is switched off. To operate the engine at starting speed without it actually starting, e.g. for testing compression pressure, unplug the connectors at the injection pump. Before disconnecting the battery of a car fitted with a radio set with anti-theft code, determine the code. Always switch off the ignition before disconnecting and reconnecting the battery otherwise the diesel direct injection system control unit may be damaged.
23
Rules for cleanliness

Pay careful attention to the following 5 rules for cleanliness when carrying out work on the fuel supply and fuel injection system: Thoroughly clean connection points and the surrounding area before disconnecting. Place removed parts down on a clean surface and cover over. Do not use fluffing cloths! Carefully cover over or seal opened components if repairs are not carried out immediately. Install only clean parts: Do not remove replacement parts from their wrapping until just before installing. Do not use parts which have been stored unwrapped (e.g. in tool boxes etc.). If the system is open: Avoid working with compressed air, if possible. Avoid moving the vehicle, if possible. In addition, ensure that no diesel fuel flows onto the coolant hoses. If this happens, it is essential to immediately clean the hoses. Always replace hoses which have suffered damage from diesel fuel.
Edition 03.98 S00.5122.50.20
------------ 23-1 ------------
23
OCTAVIA
Summary of fitting locations
Components A to F are not shown in the general illustration.
A - Diesel direct injection system relay (J322) Electrical centre page 23-3, Fig. 1 B - Glow plug relay (J52) page 23-3, Fig. 1 Electrical centre C - Blower relay (J323) Electrical centre page 23-3, Fig. 1
------------ 23-2 ------------

D - Accelerator pedal position sender (G79) In footwell at accelerator pedal 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System E - Brake light switch (F) and brake pedal switch (F47) Combined in a housing In footwell at brake pedal page 23-3, Fig. 1 F - Clutch pedal switch (F36) In footwell at clutch pedal page 23-3, Fig. 1
Edition 03.98 S00.5122.50.20
OCTAVIA
Edition 03.98 S00.5122.50.20
& 6 5 7 ' " 06 B% 6 % 7 '3 % % 0 C ' 8 1 A % ) 7 0 0@ @ 1 ! $$ )# 6 B % A ' ! (( )" 0 % ) %" ' 8 7 $ # ! 0 6 6 ! ' 4 ( 3 3 % 0 ( 2 " 1 % ' ) ( & 5 % ! $ # " % % % 9 5
23
With mechanical exhaust gas recirculation valve With intake manifold flap
3 Connector 2-pin For needle lift sender (G80)
4 Connector 3-pin For engine speed sender (G28)
3 Injection nozzle
needle
sender
4 Diesel direct injection system control With altitude sender (F96)
control solenoid
5 Connector 10-pin For fuel temperature sender (G81) For quantity adjuster (N146) For modulating piston movement sender (G149) For commencement of injection valve (N108) For fuel cut-off valve (N109)
6 Commencement o injection 7
7 Air mass meter 8
relay Only on models with optional equipment
8 Fuel
control
injection
9 Low relay Only on models with optional equipment
With fuel temperature sender With quantity adjuster (N146) With modulating piston movement sender (G149) ressure sender
Vacuum
I and sender
sender
1 - Glow plug relay (J52) 3 - Blower relay (J323)
2 - Diesel direct injection system relay (J322) 4 - Clutch pedal switch (F36)
5 - Brake light switch (F) and brake pedal switch (F47)
------------ 23-3 ------------
23
Fuel Formation/Fuel Injection
OCTAVIA
Testing charge pressure system

Testing charge pressure
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 No fault in fault memory l No leaks at inlet and exhaust side l No fault at engine/fuel injection system (commencement of injection, injectors, compression) l Engine oil temperature at least 80 C Test procedure
The charge pressure is read with the vehicle system tester V.A.G 1552 during a road test. Warning! Read measured value block 3000 rpm 1938 mbar 1978 mbar 11 69 % K-
Have V.A.G 1552 operated by a second person. Connect vehicle system tester V.A.G 1552 and select engine electronics control unit page 01-2. Read measured value block, display group 011, engine idling page 01-54.
Accelerate vehicle in 3rd gear at full throttle from about 1500 rpm. Read off figure in display block 3 at about 3000 rpm and note.
Models 04.99
Specification in display block 3: 1850...2200 mbar Models 05.99 Specification in display block 3: 1850...2250 mbar Continued for all models
If the charge pressure is not achieved, the following faults are possible: Hose of charge pressure control dropped off, leaking or blocked. Charge pressure control solenoid valve (N75) blocked or faulty.
------------ 23-4 ------------

Edition 02.01 S00.5122.52.20
OCTAVIA
Fuel Formation / Fuel Injection Operation (linkage, shaft) of the bypass valve stiff or stuck (bypass valve constantly open)
23
Final control diagnosis Charge pressure control solenoid valve -N75
K Readout in display:
Edition 03.98 S00.5122.50.20

Vacuum unit leaking Intake manifold pressure sender faulty Leak between turbocharger and intake manifold Turbocharger faulty (turbine blocked by foreign bodies) If the charge pressure is not reached: Carry out final control diagnosis trol diagnosis, page 01-20. Final conCarry out final control diagnosis and actuate the charge pressure control solenoid valve. The solenoid valve should operate and, at the same time, the linkage of the vacuum unit of the charge pressure control at the turbocharger should move back and forward (at least 3...4 times so long as vacuum is present in the vacuum reservoir). End final control diagnosis. If the linkage moves and the charge pressure specifications are not achieved: Test intake manifold pressure sender 1.9-ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Testing intake manifold pressure sender and altitude sender. Replace turbocharger. 1.9-ltr./66 kW (TDI) Engine, Mechanical Components; Repair Group 21; Removing and installing turbocharger If the linkage does not move because the solenoid valve (N75) does not operate: Test charge pressure control solenoid valve page 23-6.
------------ 23-5 ------------
23
------------
2 1 ! ! 0 0 ' ' ( 3! ) %# % " #& $

OCTAVIA
If the linkage does not move although the charge pressure control solenoid valve operates: Inspect vacuum hoses according to hose diagram page 23-9.
- Test charge pressure control pressure unit 1.9 l/66 kW (TDI) Engine - Mechanical Components; Repair Group 21; Testing operation of charge pressure control vacuum unit.
Testing charge pressure control

testers and aids
Hand-held multimeter, e.g. V.A.G 1526 A Adapter cable set, e.g. V.A.G 1594 A
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Test box V.A.G 1598/22 or V.A.G 1598/31 Diode test lamp, e.g. V.A.G 1527 B Test procedure -
Connect vehicle system tester and select engine electronics control unit page 01-2.
Select final control diagnosis and activate charge pressure control solenoid valve -N75 page 01-20.
If valve is not actuated (does not click):
K-
Unplug connector -1- of charge pressure control solenoid valve -N75 and connect diode test lamp between the contacts of the connector.
Diode test lamp must flash. Diode test lamp flashes: -
End final control diagnosis.
Switch ignition off.
Connect multimeter for resistance measurement to valve -2-.
Specification: 14...20
------------
Edition 02.01 S00.5122.52.20
1 4 " # 9 P 3 Q 6 # " D C 0 H 2 E B B # 1 4 " " 7 5 8 @ 4 " 3 " 9 7 ! 8 3 4 " 3 1 ! 6 6 1I! 1 1 # ! G " ! # 5 4 " 3 ) " 2 1 F ) ) 0 ' & % ) !( $A ( )) ) # ! " ! ! ! ! ! ) ! ! ) $
If the If the t f f f I
-----------------------
OCTAVIA
Edition 02.01 S00.5122.52.20
23
23
------------
1 & 6 # 7 5 1 2 ' # 2 & 2 ) 3 $ %7 ( 0 # 4# # ! " 0 8 40 1" 2" ' # 2 & 2 ) 30 $ % 0 ( & & # # % ! " ( " %" "
Fuel Formation/Fuel Injection For t
OCTAVIA
K Test the following cable connections for short circuit to positive and to negative, and to open circuit (connector -1-). connector 1 2 .
2, 28 15
Rectify any open circuit or short circuit in the wiring.
For t
K Test the following cable connections for short circuit to positive and to negative, and to open circuit (connector -1-). connector 1 2 .
1, 2 62
Rectify any open circuit or short circuit in the wiring.
If no fault is found in the wiring: -
Replace the diesel direct injection system control unit (J248) 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System.
------------
Edition 02.01 S00.5122.52.20
OCTAVIA
23
Hose diagram for charge pressure control, exhaust gas recirculation and intake manifold flap
1 - Vacuum positioning element for intake manifold flap 2 - Intake manifold flap changeover valve (N239) 3 - Branch 4 - Non-return valve White connection points toward charge pressure control solenoid valve -N75 5 - Vacuum unit 6 - To air filter 7 - Charge pressure control solenoid valve (N75) 8 - Pressure unit For charge pressure control valve Part of turbocharger, cannot be replaced separately 9 - Electromagnetic exhaust gas recirculation valve (N18) 10 - Mechanical exhaust gas recirculation valve 11 - Vacuum pump 12 - Brake servo unit 13 - Non-return valve
Edition 02.01 S00.5122.52.20
------------

------------
23
Read measured value block mg/s 1030 mbar 1011 mbar
------------
" ! #
OCTAVIA
Testing air mass meter
The air mass meter is required by the control unit for calculating the permissible injected quantity and for controlling the exhaust gas recirculation. The smaller the signal supplied by the air mass meter, the less fuel may be injected. testers and aids
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Hand-held multimeter, e.g. V.A.G 1526A Adapter cable set, e.g. V.A.G 1594 A
Test box V.A.G 1598/22 or V.A.G 1598/31 Current flow diagram Test procedure -
Read measured value block, display group 010, engine idling page 01-52.
Check readout in display block 1. Specification: 230...370 mg/s
10
0.0 %
If the specification is not achieved: -
Check vacuum hoses of exhaust gas recirculation according to hose diagram page 23-9.
Test exhaust gas recirculation system 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System.
If the specification is achieved: -
Accelerate vehicle in 3rd gear at full throttle from about 1500 rpm.
Warning!
Have V.A.G 1552 operated by a 2nd person. Check the readout in display block 4 at about 3000 rpm and note.
------------
Edition 02.01 S00.5122.52.20
OCTAVIA
Read measured value block 830 mg/s 1030 mbar 1850 mbar
Read measured value block 830 mg/s 1030 mbar
Read measured value block 1030 mbar 1850 mbar
Edition 02.01 S00.5122.52.20
' @ 6 8 ( 8 1 6 7 65( 2 ( 4 8 8 6 4 9 5 5 $ # ! " ) 5 A5 5 3 " ' 1 ' ( ) # & ## #0

Fuel Formation/Fuel Injection 10
23
Specification in display block 4: 100 % (accelerator pedal position)
Repeat the test and accelerate vehicle at full throttle.
10 100 %
Specification in display block 3: 1850... 2200 mbar (charge pressure)
Test charge pressure page 23-4.
10 100 %
Specification in display block 1: > 800 mg/s (inducted air mass)
Test charge pressure page 23-4.
Replace air mass meter (G70).
If the readout in display block 1 is a constant 550 mg/s (fixed substitute value): Switch ignition off. .
For
K-
Unplug connector at air mass meter (G70). Switch ignition on.
Connect multimeter for voltage measurement to the following contacts of the connector: connector
3 + earth 1 + earth 1+5 3+5
approx. battery voltage approx. 5 V approx. 5 V
approx. battery voltage
------------
------------
& # $ D F E ' $ 4 7 B @ 6 ' & # $ $ " ! " " $ ( 2 G " % ! $ ( G 2 G( " 0 ' ! % v r R X w q X X w t R R X q P w w T R P V Q Q Q # $ ( 3 & & & & ' $ ' # $ &%(1% &8 A5 ( % $ ) D8%9( C 9 5 g%% f g # ' ' u Q )pQ A V T AVI e Vs q )Q y v X T w U r R X w q X X w t R VX x S p bH U T X Y R V e c a iF `% i($ g f%% d W% hP ' G ' ( G $ ' 6 % # $ ! &b # $ ' G D F E ) U % A ' $ 4u V 7 B @ 6 2 2 3 % ' $ q & #I 9 % $( " C 0 ! s 8 u%%% p ((Q Q (( Q V%V 1%% 5%
------------
------------
23
If the
If the
the
connector
connector
the
the
Edition 02.01 S00.5122.52.20
the
OCTAVIA
E G Q h a # c f d b Y E U R " # ! ! U ! ! U $ " ' ! ! U $ ' " ' ! ! U w r 2 v 2 2 y r rV 2 v p ) r p ( qY q q % ! ` E % E E $ E " R Q EP$ E g e $ F H GTTX IW D P$ F 2 3 9 7 5% 8 4 C$ A @ 8 1 ' qT i ! S( u & I ( e(x 9 v q %) 2v ) 0 w rq 2 v 2 2 r ( ( s u 69 r p 2 3% 0 ) ( 9 4S 1 7 5 ty t$ A @ 8 BV ! " ! ( ' $ u( $ q "B #q 0 #% ! x $( i 6( % q %
For connector connector .
------------
OCTAVIA
Edition 02.01 S00.5122.52.20
KT
------------
23
E c e d W # Y b ` X U U P I G E ' # & # # @ ) A 4 ) 8 3 0 0 4 5 ( 5 ) ! ' S & P U I S' I R a H H R % @ )D$ 4 A 0 ) 8 ) ) 1 V i s s H A 4 0 )a q f f' u tR v$ r8 0 x wD v1Q p yh T 2 ! " 6 ! 1 Qg F B% 91 92 "$ #C B #2 ! 17B 72 F % 9 1 9 $
------------
------------
23
KT
connector
Edition 02.01 S00.5122.52.20
OCTAVIA
) 5 ! 7 b s c g e 4 4 )) " ) 4 " ) ( ) 3 " C 3 7 0 5 " ( ! 3 & & ) ) ! C 3 " 2 " 3 ! ( ) ) & 9 S T H S Q X S Y Y i ` " 3 ! ) 7 y y c e y y g c T H Y i ` " 3 ! d d y r c y s c Y A 4 4 ) " 4 ) " ) ( ) 3 " C 3 7 0 5 " ( ! & & 3# )9 52 !9 3 C 3 ! 2 7 % " ( 3 ! ) ) # g @ D i & BH & ) 2 5 ( ) 9 87 8 3c "9 ! ) 5 " " 3 " 3 ! 5 2 " 0 ! ) 0 ) &7 & $ 4# 82 2T " ) " 3 ( 7 3 ! " 8 3 2 ! " ! 3 % # 9S 9) & & 9 $) 4 ) ! ) 2 ) ! & 9 "s !2 32 3A# )( 86 2( "#$ ) ( ) " " 3 #r 96$1# 9 ! ) ! ( " 3 ! ) 7 2 d$B i$# u$ 4 )$$# !B ) "( !13 37 3V 2Rw 3R ! 2 7 % " ( 3 ! ) #7 sg @ D & i & 9 6RPA f )g7 5hy !uy 74 5i " )r "5 5q "( )d q40 gAuy cA4 ygf &A y ) 7S@1 3)31 52) 4$D0 !Ah) 74 %22 (g! 3A$x )#! 2 !$) )( 0H! Cr !) ) x& & &Ac& @4 DBAy &C XR5 HA Sq G( Hf Id Y7 ÀB$@0 `f 3) 3 d! d) bAA4 aAc& c13311 gAA#$) b$D0 uE 2 r2x c& aC e! e) u( r! c f" ` 5 ) ) ) ! ( ) 7 2 d bR a a s r c a @ & p `$ ) 4$$ 4 5 ) ) ) d# b11##1 a##$6 a0 qD e12 c & 9 ` 3 d d g i$A#$1 hE b a g g a g c c ` `0 8#$# 4E )& !( 2! ) ) ) ( ) % ) d0 d$ bA0 @! 92 a$#0 e#$ c 13 9 X#$0 W0# H3 H1$B V) S S VB T6 G I Y#A0$ F ) ) " 3 &# 62$# " 3 4#$# "7 !v ) 8# )1$##$ " (# ) ) 3 ( ) 3 " 0 & & 9 )#32A 3)x !` )) 2Ay 30) "#y 3! (r )A 3 2 " 3 3 7 #c #D 9#A4 @10$6! D2& &#4 9 6( 4B$50 40cf 7)q )2( "dC (t$! 4d )##e7 "& )u (1$4 )#s 3( ") C 3 7 0A 5 " ( ! &1#$cy )) "D0 &31 6&@1 4 "3 !Q y 8 )2 )$ " (# ) ) ! % " ( " ! " 0 7 #1A 9A & 9 & 6) 60 )) 70 (( 5E )A 5 " 3 ! ) ) ) 0! C 3 " ( 3 ) 2 ) C 4 3 901$1$E 90$ 9$V $7 " )PA06 !H (( "% !1 %0 ) 3 ! 0@ " ) ( 2 2 2 #! ## &T 9 9 '" 8 ) 2 " 3 3 ( 3) ") 3A# )( 20 ) %% ! ) 7 3 0" ( ! #9 #A 9 9 9AB$6 @$#V &EB$w 13 69 30( 0! ! " ! % 4A#1AR )#% "$2 5( !$#10$# 27 3$2 )##A )#0 "## !f 2 ) ( ( 0 #) # & B#$1AB A$1#$$# EU#$# A'10 #$#$$B 0E1$11# ###1 f##$ #$RP $#( #A0A# 0$##$#$ ('$$$1$ H 1A##'1$# AE## 0$## 1#0$A 1E#0
Fuel Formation/Fuel Injection K K K T The The
OCTAVIA
Edition 02.01 S00.5122.52.20
esting modulating ment sender and
The e
testers and aids
he
adjuster
he
------------
------------
23
23
------------
9 2 & 2 5 & 2 2 3 5 & & 28 @ 2 & 2 % ' 5 76 6 2 &4 2 2 % 36 6 ) $ ' % & %1 0 & ## " ! ( ( !
Fuel Formation/Fuel Injection Electrical ment -
OCTAVIA
modulating and
K-
Separate plug connection -arrow- from injection pump.
Connect multimeter for resistance measurement to the following contacts of the connector -2-. connector 1+2 3+2 6+5
4.9...7.5 4.9...7.5
0.5...2.5
If the specifications are not achieved:
- Replace injection pump. 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System. and
Separate plug connection at injection pump. Switch ignition on.
Connect multimeter for voltage measurement to the following contacts of connector -1- at the wiring loom. connector
1 + earth 3 + earth
approx. 2.5 V approx. 2.5 V
5 + earth
approx. battery voltage
If the specifications are not achieved: -
Connect test box to the wiring loom to the engine control unit 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System.
------------
Edition 02.01 S00.5122.52.20
( ! 1 6 " 0 3 0 & ! 0 ! 2 6 ! 0 1 0 9 a 0 6 g e ! 0 & " q " ! 0 2 ! 2 ! ! ! " ! # 9 p 9 $ ( 1 0 ! 0 0 & 6 $ 9 W R t I I u s ( !# 0 6 & 2 2 & 6 " 0 ! 2 7 & 2 0 3 $ $ p f a5 B B B b B a f ` b B h h d a i B b g& i B W wD 0 X& S I X R X U I 1 Y P Qb 0 I G q & B u )5# r6 #3 5f a B &'' ! 0 & 2 6 2 BD &%5))'5' &"'' 3x)@ 0C## "2 3'C !w 3 1 ! 0 8 & 53 0 3 ! & 7 8 9y2 9 %h &7 &)#)@)A "#y## 0) & ( ! " 0 0 & 2 ! 5q 3 2 1 0 50 & ! #& $! 4 #'% % )))w r% ( ! 05 62 &VvH 2T 2V & 6 " 0 ! 2 7 & 2 0 3 # $)55 $VD p fq)) f)2 `2 i##)#))%) gqA a! a)5# h a f2 ` g" b# bA eC a! d `7 c b `R a W '! X6 R S I X R X U I 0 & Y P Q0 $ # & I G & " E )q 2 2H 5AQH ##DT B AV A 6 2 &H ! 0 0 & 2 2 BF C &%& &0 37 0' "5#5 3" !#)@'# 3H 1% !)% 0)5 8H &' 51 0 3 ! & 7 8 " 6 2 9##F) % '! 9 &E &T "0 05## &D#V'# (# !#5 ")5#) 0D 0% &))5 2)# !' 5& 3 2 1 0 5)2 2 & & ! ! #52 #2 $! 4 $ )) # # #)H) #)#) ) )A Q ')))) 5) ) @#
For For connector connector . .
------------
OCTAVIA
Edition 02.01 S00.5122.52.20
KT
KT
------------
23

Manual Skoda Octavia 1,9 81kW

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Manual Skoda Octavia 1,9 81kW

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Service

Workshop Manual OCTAVIA

Service Department. Technical Information

1.9l/81 kW (TDI) Engine, Fuel Injection and Glow Plug System

Article Number S00.5122.51.20 S00.5122.52.20 S00.5122.53.20 S00.5122.54.20 S00.5122.55.20 S00.5122.50.20

Contents next page.

Printed in Czech Republic S00.5122.55.20

01-20 01-20 01-24 01-26

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

01-27 01-27 01-29

01-31 01-31 01-32 01-36 01-42 01-47 01-48 01-49 01-54

23-4 23-4 23-6 S S

23-1 23-1 23-1 23-2 S S S S S S S S S S S

Glow plug system

Technical data of self-diagnosis

Edition 10.03 S00.5122.54.20

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

08 Read measured value block

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

Edition 02.01 S00.5122.52.20

Test of vehicle systems Control unit does not answer!

Test of vehicle systems Fault in communication build-up

Test of vehicle systems K wire not switching to earth

Test of vehicle systems K wire not switching to positive

Test of vehicle systems Enter address word XX

Edition 03.98 S00.5122.50.20

------------ 01-3 ------------

038906018.. 1.9 l R4 EDC G00SG 1816 Coding 00002 WSC 01234

Coding 00002 Coding variant of control unit WSC 01234

Data status (software version) of control unit

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

038906012HC 3316 3314

For current control unit version - spare parts catalogue

Storage of non-existent faults in fault memory

Edition 10.03 S00.5122.54.20

Functions not being performed Reduction in gearbox life

K Readout in display: For the remaining procedure structions.

Interrogating and erasing fault memory

Special tools, testers and aids required

Test of vehicle systems Select function XX

K Readout in display: End output (function 06).

Edition 02.01 S00.5122.52.20

If one or several faults are stored: Press key.

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

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

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

Edition 01.04 S00.5122.55.20

K The number of stored faults appears in the display.

Test of vehicle systems Select function XX

Test of vehicle systems Fault memory is erased!

K Readout in display: Note:

Edition 02.01 S00.5122.52.20

Possible cause of fault

Line interruption of screening

Line interruption/ short-circuit to earth Supply voltage

17564 17565 17566

Short-circuit to positive -G71 defective

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

Line interruption or shortcircuit

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

Open/short circuit to positive

Engine preheater does not operate

Edition 02.99 S00.5122.51.20

- Erase fault memory and continue checking vehicle