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Manual Skoda Octavia 1,4 55kW
Manual Skoda Octavia 1,4 55kW
The Workshop Manual is intended only for use within the koda Organisation; it is not permitted to pass it on to third parties. 2001 KODA AUTO a. s.
Printed in CR
Service
Supplement Overview for the Repair Manual OCTAVIA
1.4 l/55 kW engine, Motronic Injection and Ignition System
Replaces the Supplement Overview - Edition: 03.01
Supplement
Edition: 04.02
Subject
Basic edition Changes for the engine BCA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
This document is copyright protected. Any use of this document without the agreement of the copyright owner is forbidden 2002 KODA AUTO a. s.
OCTAVIA
01 Self-diagnosis
Contents
Service
Page
General information about the self-diagnosis .......................................................................... - Properties ................................................................................................................................. - Technical data for the self-diagnosis ........................................................................................ - Connecting up the vehicle system tester V.A.G 1552 and selecting the address word for the engine electronics ......................................................................................................... - Interrogating and deleting the fault memory ............................................................................. - The fault table ........................................................................................................................... - Actuator diagnosis .................................................................................................................... - The readiness code .................................................................................................................. - Reading the readiness code ..................................................................................................... - Generating the readiness code ................................................................................................ - Reading measured value blocks .............................................................................................. - Reading measured value blocks, display group 001...009 ....................................................... - Reading measured value blocks, display group 010...029 ....................................................... - Reading measured value blocks, display group 030...049, 099 - lambda regulation ............... - Reading measured value blocks, display group 050...069 ....................................................... - Reading measured value blocks, display group 070...079 ....................................................... - Reading measured value blocks, display group 100 ................................................................
01-4 01-6 01-8 01-29 01-31 01-31 01-32 01-38 01-40 01-46 01-52 01-60 01-66 01-67
24
Fuel preparation/injection
Repairing the fuel injection system ........................................................................................... - General comments ................................................................................................................... - Safety measures ...................................................................................................................... - Cleanliness regulations ............................................................................................................ - Installed location of the individual parts of an engine with engine identification characters AXP ........................................................................................................................ - Installed location of the individual parts of an engine with engine identification characters BCA ........................................................................................................................ - Removing and installing parts of the fuel injection system ....................................................... - Disassembling and assembling intake manifold ...................................................................... - Disassembling and assembling the fuel distributor with fuel injection valves .......................... - Disassembling and assembling the air filter ............................................................................. Checking components ................................................................................................................ - Checking the lines using test box V.A.G 1598/22 .................................................................... - Checking the throttle valve control unit (J338) ......................................................................... - Testing jet formation and tightness of the injection nozzles ..................................................... - Checking the fuel pressure regulator and holding pressure ..................................................... - Checking the intake system for leaks (unmetered air) ............................................................. - Checking the intake air pre-warming system ........................................................................... Checking functionality ................................................................................................................ - Checking the lambda probe and lambda regulation before the catalytic converter ................. - Checking the lambda probe and lambda regulation after the catalytic converter ....................
Page
Checking auxiliary signals ......................................................................................................... - Checking the speed signal ....................................................................................................... - Checking the databus (CAN bus) .............................................................................................
Engine control unit ...................................................................................................................... - Checking the power supply to the engine control unit .............................................................. - Procedure if the voltage supply is interrupted .......................................................................... - Replacing the engine control unit ............................................................................................. - Coding the engine control unit .................................................................................................. - Adjusting the engine control unit to the throttle valve control unit ............................................
------------1 ------------
28
Service
OCTAVIA
28-1 28-1 28-1 28-3 28-5 28-6 28-6
Checking components and functions ....................................................................................... - Checking the hall sender (G40) ................................................................................................
Repairing the ignition system .................................................................................................... - General comments about the ignition system .......................................................................... - Safety measures ...................................................................................................................... - Removing and installing parts of the ignition system for engines with engine identification characters AXP ........................................................................................................................ - Removing and installing parts of the ignition system for engines with engine identification characters BCA ........................................................................................................................
Page
------------11 ------------
OCTAVIA
Self-Diagnosis
01
Self-Diagnosis
OCTAVIA
AXP, BCA
1 knocking sensor No No
2 lambda probes
Yes
No
Selectable functions when using the vehicle system tester V.A.G 1551/1552 The conditions under which you can select the desired functions can be taken from the following table. Function on the vehicle system tester Function Engine stopped, ignition switched on Yes Engine running, idling Yes Yes Yes No Condition Vehicle running normally on the road Yes
02 Interrogate the fault memory 04 Initiate the basic setting 2) 05 Delete the fault memory 06 End output 07 Code the control device 15 Readiness code
1) 2)
Yes Yes
Yes
Yes No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Must be undertaken after the following work has been done: engine control unit, replacing the throttle valve control unit or the engine or unclamping of the battery
Only undertake this when the ignition is switched on, when the engine does not start (actuate the starter motor beforehand for a minimum of 6 seconds)
OCTAVIA
Self-Diagnosis
01
of t for electronic panel insert (fault control) in EPC is an abbreviation for Electronic ower ontrol, which is sometimes also termed electronic throttle. After the ignition is switched on, the engine control unit checks all the components which are of importance for the operation of the EPC system. Testing operation Switch ignition on, the EPC warning light must come on. If the EPC warning light does not come on when the ignition is switched on: - Test dash panel insert Electrical System; Repair Group 90. If the EPC warning light comes on when the ignition is switched on: Start engine and run at idling speed. If the EPC warning light does not go out: Interrogate fault memory of engine control unit page 01-6.
------------ 01-3 -------------
01
Self-Diagnosis
OCTAVIA
Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit
Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Test conditions l Fuses o.k. as specified in up-to-date current flow diagram. l All electrical components such as lights and rear window heater, must be switched off. l If vehicle is equipped with air conditioning, this must be switched off. l Battery voltage at least 11.5 V. l Earth connections between engine (at clutch housing) and body (below battery) o.k. Procedure KConnect the vehicle system tester V.A.G 1552.
After the vehicle system tester has been connected: Depending on the desired function, you have to: switch on ignition or start the engine page 01-2, table of Available Functions.
Notes: If no readout appears in the display, test voltage supply for diagnostic connector Fault Finding Programme in the binder Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
If the readout in the display does not correspond to the procedure: Operating instructions of vehicle system tester
------------
HELP
-------------
If Data transmission error is displayed because of an incorrect entry, disconnect cable at fault reader, plug in again and repeat the steps.
K Readout in display:
OCTAVIA
Self-Diagnosis Note: Operate the vehicle system tester in accordance with the readout which appears on the display. Enter address word 01 for Engine electronics and confirm the entry with the key Q.
01
K The control unit identification and the coding appear in the display, e.g.: 036906032 = Part No. of control unit ( Parts List for current control unit version) ME 7.5.10 = System designation and version (Motronic) 3257 = Software version Coding 00021 = Coding of control unit, coding versions of engine control unit page 24-30 WSC xxxxx = Workshop code from V.A.G 1552 with which last coding was performed Notes: If the control unit version display does not match the vehicle, replace control unit page 24-29. Incorrect coding of the engine control unit results in: Poor performance (jerky gearshifts, load change jolts, etc.) Increased fuel consumption Increased emission levels
Functions not being performed (lambda control, actuation of activated charcoal filter system, etc.) Reduction in life of automatic gearbox If the coding does not agree with the version fitted to the vehicle: Test of vehicle systems Select function XX HELP Check coding of control unit page 24-30. Press the key.
------------
-------------
P W P 7 8 e 9 H G W 7 f X V Q 99 8C S9 G S8 9 9 G 9 8 9 H 9 G 9 I i 9 S S @ I Q D 9 G 9 8 S 9 9 P I G Q c G W i 8 Q 9 i 8 9 i h 8 7 8 q p Q h h 7A 9 iS P G 9 G S 7 IQ 8 7 8 P 8 V e e U8 9 H G W P X V H 8 9 9 9 G W i P S G S I I I i Q Q r 99 GA 9@ 8 7 9 G W i S IG P G S 9 A Q Q Q b ' ! ( x ' ! '`A !5A (A ! 2 $ ( $ $ 0I ! y5 0 & 3I`5 9 i 9 C p 'E5 !b 2 (g (A ' $ 3b 8 G 9 W W G G W i S Q Q r 5x P G S 9 7 H9 77 9b h PI @Q GE 7 I@ 7 9 P Ab Q s c U b `S hh 9G9 i8S hS 8 97 iP 8I 7I 8 G @ 7 I q@9 pIh Q 5`C9 h9QDAE 9PG P9S GS7 9h G9 H9 7i 9r 8@ 7G 8u 7 8 P 9 8 I AEG fB VS eA b5 8EA9Eb 7DDSDA 89 HS 7i QC 87 9@5 8C GDRIA 8`EI 7gDAb 9bb SS @ S G P 7 7 9 G 9 W A7 CIAI Q9 QIAD a dED c 9 H G W Y X V T@ 7S I9 90 SAb GE0 Sy 8 P 7 8 7 IADb 9 H QA&bAE U8 V8 QIb QADA 59 87 99 8ww G%DI 8Iw GIA H%A 8& 8I 8I PEb 95 8 H 8 9 G 9 QIbD Q&A F 9E5 9 @ 9 8 8 B 7 @ 6 C 2v ! ' ! " 0 3 4 ) 20% 1A0 !@ !t (bw 0EB 0IDA $ " ! 0I !I (# ' !DA ' ( 3RbUv #8 IDADDbQDAE &D%uDD9b IA8 A&H 5D% EbU7 `At E59 5P @ S u bDEA iG ` I UAA# bD& 5
-------------
------------
01
Self-Diagnosis
other.
If you have switched off the ignition between Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Note:
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
the
the table
starter switch
memory has to
the
and
are
the
the
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with the
or .
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with the
the
to the
it is the
OCTAVIA
OCTAVIA
Self-Diagnosis
HELP
K The automatic test sequence is completed once the following readout appears in the display: Erase all the fault memories and then conduct a road test.
!
01
test When carrying out test and removal and installation work, it is possible that other control units detect faults, such as connectors unplugged. For this reason, it is necessary to interrogate and erase the fault memories of all the control units once the work is completed. To do this, you must: Press the key 0 twice for the address word Automatic test sequence and confirm the entry with the key Q. V.A.G 1552 thereupon sends all the known address words one after the other. If the control unit answers with its identification, the number of stored faults or No fault recognized appears in the display. Any faults which are stored for a system are displayed one after the other. After this, V.A.G 1552 sends the next address word. Observe the safety precautions applicable to a road test page 24-2. During this road test, the following operating conditions must be met: The coolant temperature must rise to more than 85 C. Once this temperature is reached, the following operating states must be achieved several times: Idling speed Part throttle Full throttle Enrichment Fuel shutoff on overrun Engine speed must be increased to more than 3500 rpm at full throttle. Once again interrogate the fault memories of all the control units with the Automatic test sequence. End output and switch ignition on.
------------------------
01 Fault table
Notes:
Self-Diagnosis
OCTAVIA
Explanations:
The fault table is arranged in accordance with the 5digit fault code which appears on the left.
Explanations on fault types (e.g. open circuit/short to earth): Operating instructions of vehicle system tester
Intake air temperature sender -G42 = faulty current path or fault location Signal too small = fault type as text Sporadically occurring fault = fault no longer present, e.g. loose contact
If components are shown as faulty: First of all, test the cables and plug connections to these components as well as the earth cables of the system on the basis of the current flow diagram. Replace the component only if these tests do not reveal a fault. This applies in particular if faults are displayed as occurring sporadically (SP). When testing earth cables, rectify any open circuit in wiring or short circuit according to the current flow diagram: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder.
Readout on V.A.G 1552 16490 Intake manifold pressure/air pressure G71-/-F9616491 implausible signal
When testing senders, injectors and other components of the fuel injection system, use the current flow diagrams binder.
Intake manifold pressure/air pressure G71-/-F9616496 signal too small - Test sender -G42
Intake air temperature sender -G42 16500 signal too large - Test sender -G62
OCTAVIA
Self-Diagnosis
01
Readout on V.A.G 1552 16501 Coolant temp. sender -G62 16502 signal too small
Rectifying fault - Test sender -G62 - Test coolant thermostat: 1.4 l/55 kW Engine - Mechanical Components; Repair Group 19
Coolant temp. sender -G62 16514 signal too large - Test lambda probe heater upstream of catalytic converter pae 24-24
Bank 1 probe 1 16515 electr. fault in circuit - Test lambda probe and lambda probe control upstream of catalytic converter page 24-24
Bank 1 probe 1 16518 signal too slow - Test lambda probe and lambda probe control upstream of catalytic converter page 24-24 - Test lambda probe heater upstream of catalytic converter page 24-24
------------
-------------
01
1 ) ) ' 0 0 1 ) ) ' 0 0 # & && ! ! # ! " ! $ ! $ 3'& 1& '(& % ( ( ! $ 22 &
Self-Diagnosis
OCTAVIA
on
- Test lambda probe and lambda probe control upstream of catalytic converter page 24-25 - Test lambda probe heater upstream of catalytic converter page 24-26
no activity 1
malfunction fuel
- Test fuel pressure regulator and pressure in system page 24-19 - Test injectors page 24-17 - Test fuel pump: 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20 - Inspect intake system for leaks page 24-22 - Inspect vacuum lines for leaks
OCTAVIA
01
- Test fuel pressure regulator and pressure in system page 24-19 - Test injectors page 24-17 - Test activated charcoal filter solenoid valve page 01-29, Final control diagnosis - Test injectors
engine speed 2 TV
- Inspect engine for mechanical damage and erase fault memory page 01-6 - Test engine speed sender - Test throttle valve control unit page 24-16
16606 Angle
implausible signal 2
TV
Angle
TV
0 8 % ! % " 9 @ @ 0 8 % ! % " 9 @ @ 8 % ! % 9 @ 2 5 8 % ! % 9 @ 4 5 8 % ! % 97 &6 @ 5 8 ! % 97 &6 5 0 !& ! ( ' ( ' " % % 1 07 2"6 0 !" " !&& ( ' ( % % 1" 07 206 " 3 1 4 2 ! &"7 "6 ') () '" )& && 0 % % ! "$ " " ) ) ) & 8& A@#7 !0 % %6 & $' & $ )"" )
short to positive short to earth short to positive short to earth short to positive short to earth signal too large signal too small implausible signal 1 on ------------- Test injectors - Test sender -G79
------------
01
Self-Diagnosis
OCTAVIA
OCTAVIA
4 ' ' 5 " 6 1 1 2 3 4 ' ' 5 " 6 1 1 2 3 & $ $ 0 ' ' 1 1 # % # " " & $ $ 0 ' ' 1) 1 # % # 2 " & $ $ 0 ' ' 1) 1 # % # " $ $ ( ( 0 ( ( ' ' ( ( 1) 1( % " $ $ (( ( 0 ( ( ' ( ( 1)( 1( ) ( " ! !( ! !( &( 0 8# % ('( & 7 )# # )&
Self-Diagnosis
01
- Test injectors
16655
short to earth
short to positive
Test injectors Test ignition cables and spark plugs page 28-3 Test ignition coil Test combustion misfiring
Engine
implausible signal
Engine
no signal
------------
-------------
01
Indicator on the V.A.G 1552 16711 Knocking sensor 1 -G61 16712 Signal too small
Self-Diagnosis
OCTAVIA
Knocking sensor 1 -G61 16725 Signal too large - Check sender -G40 Page 28-5
Camshaft position sensor Sender -G40 16791 Signal too large - Check the exhaust gas recycling Page 01-29 Actuator diagnosis - Check sender -G212
Potentiometer for the exhaust gas recycling -G212 16792 Signal too small
Potentiometer for the exhaust gas recycling -G212 16804 Signal too large - Replace the catalytic converter 1.4 l/55 kW engine mechanics; Rep. Size 26
Effect to weak
OCTAVIA
$ 7 7 1 6 ' 8 # 9 ! ! ! ! ! $ 7 7 1 6 ' 8 # ! 4 3 $ 2 1 5 " 0 " # ! ( % & & % ) ! ( % & & % ! ( # & & %% ! $ ! (#% 2& # ' $ " # @ 8 % 8
Self-Diagnosis
01
malfunction
- Test -N80 page 01-29, Final control diagnosis - Inspect hoses and connection pipes from fuel tank to throttle valve control unit 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20
faulty flow
implausible signal
Voltage
implausible signal
- Test voltage supply to engine control unit page 24-27 - Test alternator and battery: Electrical System; Repair Group 27, Battery - Procedure in the case of voltage interruption page 24-28
Voltage
Voltage
- Test earth cables according to current flow diagram - Replace engine control unit page 24-29
unit
------------
-------------
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short short short short 1 1 1 1 1 1 on too too ------------to to to to 1 too too
------------
01
Self-Diagnosis
short
to
OCTAVIA
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Readout on V.A.G 1552 system too rich system too system too system too rich limit limit 1 2 1 est est est l/55 kW est system est system l/55 kW est EGR l/55 kW est system est est est est est est est est est est est est est est est
OCTAVIA
Self-Diagnosis
system
system
system
system
------------
-------------
01
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01
Self-Diagnosis
of
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OCTAVIA
26
26
20
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Readout on V.A.G 1552 electr. fault in circuit electr. fault in circuit electr. fault in circuit electr. fault in circuit electr. fault electr. fault 1 1 1
OCTAVIA
Self-Diagnosis
------------
-------------
01
01
Readout on V.A.G 1552 17622 Injector cyl. 2 -N31 17623 short to positive
Self-Diagnosis
OCTAVIA
------------
-------------
OCTAVIA
2 0 3 0 8 3 0 3 0 4 ( 7 4 2 3 3 0 3 0 0 65 "5 4 ) ( 0 2 5 9 3 3 0 3 5 0 6 " ) ( 4 # ' ( " ( # " 1 ( " 1 ( " " % & $ # ! " %A B" 0' A @ 5' ' 5
Self-Diagnosis
01
- Test injectors
open circuit
- Refuel vehicle
too low
- Change type of fuel - Test knock sensor - Eliminate abnormal engine running noises (loose ancillaries, bent brackets or bolt) - Test cables and plug connections according to current flow diagram - Slacken knock sensor and then tighten again to 20 Nm
pos.
short to earth
pos.
open/short to positive
pos. sens.
incorrectly assigned
------------
-------------
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short to short to earth short to earth short to earth 1 unit gas on ------------1 1 system est est est earth est
------------
01
Self-Diagnosis
to
OCTAVIA
OCTAVIA
3 $ ! " ! 4 3 $ ! " ! 4 3 $ ! " ! 4 0 ( ' ' ) 2 3 $ ! " ! 2 ( ' ' ' " " ) 0 % & 2 1 ( ' ' ' " " ) 0 % & 1 1 ' ' ' " " ) 0 % & ' " " ) % & # " ! $ ( ( # 7 " 0 ' 5 6 6'
Self-Diagnosis
01
short to positive
short to earth
- Test valve -N80 page 01-29, Final control diagnosis - Test fuse 43
open circuit
EGR
-G212
EGR
open circuit
EGR
-G212
EGR
-G212
EGR
-G212
implausible signal
------------
-------------
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electr. fault in circuit signal circuit valve on ------------1) 1) 1)
------------
01
Self-Diagnosis
unit unit
unit
OCTAVIA
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Engine Readout on V.A.G 1552 fault in electr. fault in circuit engine fault in unit unit unit unit unit unit Electrical engine Electrical
OCTAVIA
Self-Diagnosis
engine
engine
engine
engine
unit
unit
unit
unit
unit
unit
unit
if
unit
unit
fault
unit
------------
-------------
01
01
------------
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Self-Diagnosis
OCTAVIA
on
oltage
- Test supply voltage of engine control unit page 24-27 - Carry out procedure if interruption to supply voltage page 24-28 - Test fuse
oltage 1
30
unit
unit
- Test earth cables according to current flow diagram - Replace engine control unit page 24-29 - Test databus page 24-35
-------------
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Read fault Readout on V.A.G 1552 signal too signal too 2 2 unit signal of
OCTAVIA
Self-Diagnosis
to
------------
-------------
01
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electr. fault in circuit
------------
01
The
unit
fault
fault
fault
fault
circuit
on
-------------
Self-Diagnosis
fault
unit
he
OCTAVIA
OCTAVIA
Self-Diagnosis
01
------------
OCTAVIA
l On vehicles fitted with air conditioning, the air conditioning must be switched off.
l There must not be any faults stored in the fault memory; rectify any faults present and erase fault memory page 01-6; Interrogating and erasing fault memory.
Connect vehicle system tester V.A.G 1552 and select address word 01 Engine electronics. The ignition must be switched on for this step. Enter function 03 Final control diagnosis and confirm entry with the key Q.
solenoid
Press
key.
K Readout in display:
The activated charcoal filter solenoid valve must be heard to continue clicking until the next control element is actuated by pressing the key.
If the solenoid valve is not actuated (does not click), test activated charcoal filter solenoid valve. of
Press
key.
K Readout in display:
EGR valve -N18 (inlet of engine compartment at cylinder head) must be heard to click.
If the solenoid valve does not click, Test EGR valve -N18. Note:
After final control diagnosis is ended, the ignition must be switched off. If the ignition is not switched off before the engine is next started, the engine will not start as the injectors and the ignition transformer are not operated.
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OCTAVIA
Self-Diagnosis
K Readout in display:
K Readout in display:
" " 0 ) ! # ( "' " % ' " % " ' % )" & $ ' $ '
01 Readiness
The readiness code is an 8-digit numerical code which indicates the status of the diagnoses which are of relevance for exhaust emissions. If the diagnosis for a system (e.g. secondary air injection system) has been successfully completed, the corresponding place of the numerical code is set from 1 to 0. The readiness code 00000000 means that the individual diagnoses are successfully completed. The diagnoses are carried out in regular intervals during normal driving. After completing repairs to an exhaust-relevant system, it is recommended to generate the readiness code as this then ensures that these systems operate in accordance with specification. If during a diagnosis a fault is detected, this is entered in the fault memory. The readiness code is erased each time the fault memory is erased, or if the power supply is interrupted.
Reading
t
and aids
Connect vehicle system tester V.A.G 1552, switch the ignition on and select the address word 01 Engine electronics page 01-4.
Enter function 15 Readiness code and confirm the entry with the key Q.
Once all the diagnoses have been successfully completed, the following readout must appear in the display:
00000000: meaning page 01-32 End output and switch ignition off.
One of the existing diagnoses was not successfully completed: Press the key.
------------
-------------
01
Self-Diagnosis -
OCTAVIA
Generate the readiness code page 01-32. Meaning of the 8-digit numerical block of the readiness code The readiness code is only generated if all the readout places are 0 1 2 3 4 5 6 7 8 0 Catalytic converter
Diagnosis function
Catalytic converter heater (no diagnosis at present/always 0) Secondary air injection system Activated charcoal filter system (fuel tank ventilation system)
Catalytic converter heating (no diagnosis at present/always 0) Lambda probe Lambda probe heater
0 4 # $ 0 & H & # $ $ B )G 2 & 7 3 $ " @ % 7$ 4 4 % 4$ $$ ' $ % ( )6 & 3 6 $ $ I ( $ % 1 # $ 0 $ E & 3 8 # % 98 4 4 $ 4 % B $ $ % $ 0 $ 0 % A ' 1( #0 4 $4 4 $ 4 % 8 @ 88# " 0 4 4$ $ 4 $ $ 4 % % 16 0 %A R 4 4' 8 % $ 7 % & 6 3%D8 4 $ $ 0 5 $ I ( %8 B8 1' $ #$G $7 04 " # Q & ( % ) 2Q8 8 $ $ %# 7 Q $ 88P P " 5 4 #A % % %9B !64 & G C $ 88D A % 8888)55)5C'D8888Q888 88Q 99
Self-Diagnosis K K K K Step 3: Adaptation of throttle valve control unit to engine control unit If you have switched off the ignition between Interrogating fault memory and Erasing fault memory, the fault memory is not erased. Note: The readiness code is reset or cancelled each time the fault memory is erased. Note: Step 2: Erasing fault memory Step 1: Interrogating fault memory It is essential to follow the order of the steps otherwise the readiness code cannot be successfully generated. Note: Procedure in in in t in t t
------------ 01-33 -------------
OCTAVIA
01
01
------------
# " $ !
Self-Diagnosis
OCTAVIA
60
K Check readouts in display zones 3 and 4: Display zone 3: 0...8 Display zone 4: ADP runs, ADP o.k. -
If the readout does not appear as described: Test throttle valve control unit page 24-16. Diagnosis of
ageing
Select function 08 Read measured value block and display group 030.
30
K Check operating state of lambda control upstream of catalytic converter (display zone 1): Specification: 111 -
Check operating state of lambda control downstream of catalytic converter (display zone 2): Specification: 111
Notes:
The first place in the 3-digit numerical block changes between 0 and 1 (lambda probe heater off and on). A 0 or 1 may be displayed alternately in the 3-digit numerical block for the lambda control operating state.
Readout in display zones 1 and 2 is not set to value 1 until the catalytic converter temperature is more than 400 C ( display group 34, display zone 2). The third place in display zone 2 changes for a short time from 0 to 1 (the specification is reached as a result).
Test OFF
K Readout in display:
-------------
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Self-Diagnosis K This process may take a few minutes. Note: Diagnosis of l
------------------------
OCTAVIA
01
a " d e e " a c f e y P H P D 9 P! R B C H D P P I D E C U H P C E T V 9 9 V X & 6 3 6 & 7 1 & 0 & 1 7 0 1 ' 5 1 0 1 8 % $ 2P S " Q # I b " q c c b b " a " gP s e " b ! "& @ c c !C "! ud " t " %## s f C " !! ! a a P bU " YU eUT e " @ P b@ B T@T QT " " a V b%% "3 & %8 " " a " c % c b) %% 4 a " t a ! ! c # b# " " a " ! w v x x uq b h ! " " t a " ! f d ve p a a ! ! # b " a " " e e! f s e e s s d f ! !! c ` r ! "d ! !#! c w p " q d b h! i#d b !d a " " a " ! g f e c ` R A B! C P B A P D S A X 9 X Da D!d! CC Bd@!#d E At E H D P! E! S P W U C C P P S E H 9d# V Q @! R!b P P S!# D H## I GT Pq H E E I C I D E G D C B E A E T 9e 9 6 &F2 5F## &%#@!% 74! 0 0!y 3x 1! 1 8A 0 8V ' & %P %b $ "D !"e e @f uv F!U@d Yq@c QT !# U#Q ! x F) !!e !! ! ! !Uu e ! #( f! d TFT !! e! @g F
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------------
01
Self-Diagnosis
This
Note:
Note:
is
Diagnosis of
Diagnosis of
is
filif
OCTAVIA
OCTAVIA
System in basic setting 70 0.0 % 0.0 %
01
est OFF
K After the engine control diagnosis is started, the message in display zone 4 switches from Test OFF to Test ON. Continue running engine at idling speed until the specification TVV o.k. appears in the display zone.
If the message described does not appear: Interrogate fault memory page 01-6.
Diagnosis of
gas
HELP
K Readout in display: -
Select function 08 Read measured value block and display group 075.
75 est OFF
K Readout in display: -
Engine speed must reach at least 1800...3600 rpm, coolant temperature must be greater than 70 C. Take foot quickly off accelerator to produce deceleration mode. Readout in display zone 4 jumps from Test OFF to Test ON.
Braking phase must last about 8 seconds. Check readout in display zone 4. Specification: Syst. o.k.
If the message described is not displayed: Repeat braking phase several times.
If the message described again does not appear: Interrogate fault memory page 01-6.
------------
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01
------------
OCTAVIA
Pay attention to the following points if it is necessary to operate test and measuring equipment during a road test: Always attach the test and measuring equipment to the rear seat and have it operated from that point by a second person.
If the test and measuring equipment is operated from the front passenger seat, the person sitting in that seat may suffer injuries in the event of an accident in which the front passenger airbag is deployed. and aids
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C est conditions
l All electrical components such as lights and rear window heater, switched off. l If vehicles equipped with air conditioning, it must be switched off.
l There must not be any fault stored in the fault memory page 01-6. l Coolant temperature must be at least 80 C Measured value block 004, display zone 3.
Connect vehicle system tester V.A.G 1552. Start engine and select the address word 01 Engine electronics page 01-4.
Select function 08 Read measured value block and confirm the entry with the key Q. Select desired display group number from page 01-40.
Note:
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OCTAVIA
Self-Diagnosis
01
------------
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Self-Diagnosis
OCTAVIA
001 -
Engine idling
xx.x %
xxxxxxxx 4
Coolant temperature
Setting conditions
-25.5...25.0 %
1x111111
page 01-41
of
zone 1 - Engine
(idling
on V
1552
of
- Test throttle valve control unit page 24-16 - Test idling speed
Large quantity of unmetered air (cannot be compensated by idling speed stabilisation) Throttle valve control unit jamming or faulty
- Inspect intake system for leaks page 24-22 - Interrogate fault memory
page 01-6
- Inspect intake system for leaks page 24-22 - Test throttle valve control unit page 24-16 - Test idling speed
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OCTAVIA
Self-Diagnosis
01
Analysis of indicator group 001, indicator field 4 - setting conditions 1 2 3 4 5 6 7 1 8 Meaning, when display position - 1
The engine speed is below 2000 r.p.m. The throttle valve is closed Lambda regulation in order
01
Engine load
Injection time
Self-Diagnosis
OCTAVIA
xxx mbar 4
Specification
Analysis
page 01-42
Rectifying fault
- Test solenoid valve for activated charpage 01-29, Final control dicoal filter agnosis - Test quantity injected
Incorrect injectors with larger flow installed Fuel pressure too high
Increased engine load caused by electrical components, AC, gear engaged or power steering at full lock
Rectifying fault
Large quantity of unmetered air between intake manifold and air mass meter Additional load from ancillaries
- Eliminate load (AC, power steering etc.) - Test intake air pressure sender -G71
OCTAVIA
xx.x BTDC 4
Readout when accelerator pedal fully depressed is approx. 100 %. Display group 004 - Basic functions
Engine idling xx.xxx V 2 xxx.x C 3
xxx.x C 4
Coolant temperature
As soon as a fault relating to the coolant temperature sender -G62 is stored in the fault memory, the engine control unit uses the intake air temperature as a substitute value for starting the engine. The temperature then rises in line with a model curve stored in the control module. After a certain time, a fixed substitute value is displayed for an engine at operating temperature. This fixed substitute value is, in turn, dependent on the intake air temperature. Note on display zone 4: The readout should be greater than the ambient temperature.
Self-Diagnosis
01
Ignition angle
Specification
Analysis
page 01-40
-30.0...120.0 C 80.0...110.0 C
Specification
Analysis
11.500...15.000 V
page 01-40
01
Self-Diagnosis
OCTAVIA
Analysis of display group 004, display zone 2 - Supply voltage of engine control unit
Readout on V.A.G 1552 less than 11.500 V Possible cause of fault Alternator faulty, battery severely discharged Rectifying fault - Test alternator and battery voltage, charge battery: Electrical System; Repair Group 27; Battery - Increase engine speed slightly for a few minutes and switch off ancillaries - Test voltage supply of engine control unit page 24-27 - Eliminate current drain - Test voltage, replace regulator if necessary - Interrogate fault memory page 01-6
Battery subjected to high loads just after start because of high charge current and ancillaries Contact resistance in power supply or in earth connection for engine control unit greater than 15.000 V Current drain although ignition off Voltage regulator at alternator faulty Excess voltage caused by jump-starting or quick-charger
OCTAVIA
Self-Diagnosis
01
Analysis of display group 004, display zone 4 - Intake air temperature Note: Use only gold-plated contacts for repairing the contacts in the plug connection of the sender.
Readout on V.A.G 1552 constant -40 C constant 129 C Possible cause of fault
Text 4
Engine load
Vehicle speed
xx.x % 4
Engine load
The entire temperature range is stated as a specification. The readout must be above the ambient temperature.
Rectifying fault - Test intake air temperature sender -G42 K Readout in display K Display zones Operating state (idling, part load, full load, enrichment, overrun) Specification Idling Analysis 12.0...40.0 % 0 km/h page 01-46 page 01-40 K Readout in display K Display zones Altitude correction factor -30.0...120.0 C 12.0...40.0 % -50.0...20.0 % Specification Analysis page 01-45 page 01-46 page 01-40 ------------ 01-45 -------------
01
Readout when accelerator pedal fully depressed is approx. 100 %. Analysis of display group 010, display zone 2 - Engine load
Readout on V.A.G 1552 less than 12.0 %
Analysis of display group 010, display zone 3 - Throttle valve angle, potentiometer 1
Readout on V.A.G 1552 greater than 5 % Possible cause of fault
------------
Self-Diagnosis
OCTAVIA
xxx.x %
xx.x BTDC 4
Engine load
Ignition angle
Specification
Analysis
Rectifying fault
- Test injectors - Replace spark plugs if necessary - Switch off electrical components
- Turn steering wheel into straightahead position - Test throttle valve control unit page 24-16
Rectifying fault
Engine control unit not adapted to throttle valve control unit Throttle valve potentiometer in throttle valve control unit faulty Throttle valve jamming
- Adapt engine control unit to throttle valve control unit page 24-32 page 01-6 - Interrogate fault memory
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OCTAVIA
) A 86 B B 5 8 7 5 0 2 2 1 9 3 @ G a $ Q V T P4 A& P `3% 53B 83B 26c 147 6 49 H1 @cU H I @ G $ S % % D F )&! A4P 85 7E 51 07 21 2 12 86" B@Pc B 56dU 933B3 34W @3X 3b 35 " 5 ' R & & 6 ! ! ! #R % $
Self-Diagnosis
01
Driving
Text 4
Engine load
activated 0
650...5700 rpm
12.0...100.0 %
page 01-47
of
3 - otal of ignition
of
on
greater than 0
Spark plug faulty Ignition cable termination faulty Ignition coil faulty Power output stages for ignition coil faulty Injector faulty
- Test spark plugs and ignition cable with termination - Test ignition coil - Test injectors
Driving
Text 4
activated 0
page 01-48
------------
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01
Self-Diagnosis
OCTAVIA
on
of
greater
plug faulty cable termination faulty coil faulty output stages for ignition coil faulty faulty
est spark plugs and ignition cable termination est ignition coil est
Driving
ext
K Readout in display
Display zones
activated
misfiring cylinder
page
------------
-------------
OCTAVIA
5 6 S d j 0 X 4 5 6 j j k l ( 2 0 5 4 6 g 7 4 7 d d 6 4 6 S 5 ( 5 6 S d $ 7 f % 5 6 S 5 6 e d7 uUTs P D G A UT @ I5 E sXI f4 4 H r6 b ` $V XX 4 4 YThTiS 2S (X 0 %4 )4 % 0 %5 %5 $( X U XX 5 4 5 S Y'V5 2VXgcUT (6U 0V %u4 )Vf %ES 0# % % $T XVX VX4 5 S YT 2'VQ (VT 0V6X %V )$t %X 0 % % $T V@ V2U XCVUT 6e 5T U YUBV# 2'VA (V55 05 %pB )6f %C 04$ %S %hU 'VF R PIB5u 6pS 5 4F 7U5 GEV Q5 Qh DCx GDpU FV3 D# 9@ A@ AiTD @QR ES$ HT 80 BUuv I1) CQ% BVD0 Bqy B 2 1 (T' )V ( ) ( ) ( ' ) ' $ T'U %E aTT' !aR !U #0 RUT "a w Tw
Self-Diagnosis
01
ignition -
Driving
xx.x
xx.x
control
page
page
by knock control
by knock control
page
page
angle
on
of
sensor
connection corroded
to
again
one cylinder
ers
Engine damaged
loose components
------------
-------------
u @ 5 y r r i i i x u r B i i i F i F $ q ' g ( 5 r F D F i E i F i i $ q 0 'A gA (Q 5A rA3 F' DA FA iQ EA i7 F i i dAAg a7Q e) eVA' X( aV9 `A' X( S65 U9 U T' ' Q 4 bh2 R32) VQ c0 V2 8 8 D E $ 7 5 ) u)2 @0 5B Q y) rQ r" iA9' iQ it x0 AA" A0 AH u'Q ' r BA0 iAQ iA@ ih4 F( i0 F9Q t 0 Q 0 $ A5Q AP' AQ q(4 7g 75 7 '9AE gGG ((g 5WQ '6t Q' Q 0Q hg ( 99 0 rCAg363 FCAsv3 F0h iFQ )6) DA4w EA' i( F! i7 i 7 0 Q23 92 2 s $Q A) Ah' Ag q'Q 78 (9 'Y436' gI6 (sG 5Q26C 0h hg (39 '8 92 0 rCAf F)g iQ' )t 32) 65 3Q DAQ2 E0 i(9 F99639 iQ iH FCAD dI3C PF (332 5 4A a9A' e') eQ Xs3 a0 `Ah28 X068 S3 U)f5 U'8 T7$ '8 Q 08 42g Y13$ bQ R$8 V)' c& W(4 VA76Q V)332 V9# H G @ 8 8 8 8 8 8 8 8 5 D8 B E D3 E C &3C9 $ $3 13Q 38 7g 0 (9 'w8 (4A 5) 4' 28 )5 )fA 6A8 32 2A3 f8 6 8 A "3v "8 6 3 F !9 #8 8
Read measured value block Read measured value block
------------
01
Driving
Driving
-------------
load
load
angle
angle
angle knock
angle knock
Self-Diagnosis
in
in
knock
knock
OCTAVIA
OCTAVIA
Display group
Driving Control unit in function 04 Initiate basic setting 4 xxx.x % 2 xxx.x C 3 Text
Engine speed
01
display
angle retardation
of fault
Knock sensor incorrectly tightened Engine components loose Poor quality fuel Plug connection corroded Engine damage
- Slacken knock sensor and tighten again to 20 Nm - Tighten loose components - Change grade of fuel - Test knock sensor
ignition -
sensor
K Readout in display
Engine load
Coolant temperature
K Display zones
Syst. o.k.
Analysis
40.0...110.0 C 15.0...100.0 %
page 01-44
2200...5700 rpm
------------
-------------
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Read measured value block
------------
01
Notes:
400 C (
A0
The
xxx
Engine idling
-------------
xxx
probe operational
control active
probe
control
on
K Readout in display
2).
catalytic converter
Self-Diagnosis
01
099 -
Specification
control
OCTAVIA
OCTAVIA
g qi 3i 2i h h h 2 h h 2 g i i gb X d X q7 3ic 2e5Y hg h h 2 h h 2 Via V9 V95 Vc 4 ) D C B 6 Ti` Si9 Q98 Fe H7 H` G@0 RD UD` E6 PA IiX Iff I3 ) 0 & 2 5a 9 '8W $5 c59 ( 'Y W '% $ 5 # "` " ! " ! 89
Self-Diagnosis
01
Engine idling
K Readout in display
nalysis
page
page
Low values indicate that the engine is running too rich and for this reason the lambda control produces a leaner mixture. High values mean that the engine is running too lean and the lambda control therefore produces a richer mixture. All the learned values are reset if the control unit is de-energized.
add = additive - The fault (e.g. unmetered air) always has a far less pronounced effect as engine speed rises. In the case of the additive learned value the injection time is altered by a fixed amount. The amount is not dependent on the basic injection time. mul = multiplicative - The fault (e.g. faulty injector) has an increasingly pronounced effect as engine speed rises. In the case of the multiplicative learned value this is a percentage change in the injection time. This change is dependent on the basic injection time. Learning conditions for idling speed. Coolant temperature at least 80 C, intake air temperature max. 90 C.
Learning conditions for part load. Coolant temperature at least 80 C, intake air temperature max. 90 C.
------------
-------------
01
------------
H32 H8 H 3DCD IE 3 Q)F PB 00( G01 )G 4D) 4C FC (2) F 5 %9 6 4 #4A6 ! ' #0 " !@ &@ $ 3 7
Self-Diagnosis -
OCTAVIA
of d
1 and
learned
on
of
Low lambda idling learned values with normal lambda part throttle learned values: oil dilution (high level of fuel in oil) possible Injector leaking
- Test injectors
Solenoid valve for activated charcoal filter constantly open Lambda probe heater faulty or lambda probe dirty
- Test solenoid valve for activated charcoal filter page 01-29, Final control diagnosis
High lambda idling learned values with less high lambda part throttle learned values: unmetered air possible in intake manifold area Injector leaking
- Test fuel pressure regulator and holding pressure page 24-19 - Rectify cause
-------------
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Edition 03.01 S00.5133.50.20 Read measured value block
OCTAVIA
The readout to
Engine idling
there
Self-Diagnosis
in
the
the
------------
-------------
01
01
The period indicates the time between two voltage jumps (e.g. rich - lean - rich) of the lambda probe and is thus a measure for the state of ageing of the lambda probe. If the specified period is exceeded, B1-S1 n.o.k. appears in the display zone 4. -
------------
1 C5 @8 D5 D5 7 @ 9 7 2 4 4 3 A6 5 B G $F ($ ( ) H # # $ ( % " 1% C! @## D% D" 7" @ 9$ 7% 2 4 4 3 A(% 58 B6 5( ( $& (5" ( ) # #$ %! %% # %$ # (' %5 ! " ! '
Self-Diagnosis
OCTAVIA
Control unit in function 04 Initiate basic setting Brake pedal operated Vehicle stationary, engine running at fast idling speed xxx.x C 2 x.xx 3 Text 4
Engine speed
Result of ageing test of lambda probe upstream of catalytic converter (test OFF/test ON/B1-S1 o.k./B1-S1 n.o.k.)
B1-S1 ok
0.7...2.00
of
Engine idling
Text 4
Test lambda probe downstream of catalytic converter (Test OFF/Test ON/B1-S2 ok/B1-S2 nok)
B1-S2 ok
page 01-57
-------------
OCTAVIA
$ '# ! (" " '' % " & " " ) ! %
Self-Diagnosis
01
A voltage jump from 0.700...0.900 V to 0.000...0.300 V and vice versa takes place at transition from rich to lean and vice versa ( = 1.0). In view of the steep voltage jump, the lambda control is not able to maintain constant the ideal mixture composition which corresponds to = 1.0. The control constantly fluctuates back and forward between the slightly too lean and slightly too rich states. Control value difference between rich and lean mixture is approx. 0.630 V.
The voltage signal lean mixture (large level of residual oxygen) is at approx. 0.000...0.300 V.
The voltage signal rich mixture (low level of residual oxygen) is at approx. 0.700...0.900 V.
K Voltage of 4-pin lambda probe U in mV A: Lambda probe voltage high high CO level
rich mixture (fuel excess or air deficiency) B: Lambda probe voltage low low CO level
display zone 1 -
of
Rectifying fault
constant 0.400...0.500 V
Short circuit to positive caused by: Lambda probe Lambda probe cable Earth cable Engine control unit Open circuit in wiring caused by: Lambda probe Lambda probe cable Earth cable Engine control unit Short circuit to earth caused by: Lambda probe Lambda probe cable Earth cable Engine control unit
- Test lambda probe voltage downstream of catalytic converter page 24-25 - Test lambda probe cable downstream of page 24-25 catalytic converter
constant 0.000 V
------------
-------------
01
Engine load
Ignore
Text 4
Note:
Depending on operating state of the engine, the lambda probe heaters are switched on or off, in other words the readouts in display zones 2 and 4 may either be Htg.b.(a.)C.ON or alternately Htg.b.(a.)C.ON/Htg.b.(a.)C.OFF.
Self-Diagnosis
OCTAVIA
Specification Syst. ok
Analysis
0.000...1.000 V 12.0...40.0 %
Specification
Analysis
OCTAVIA
Self-Diagnosis
System in basic setting 46 xxxx rpm 1 K Readout in display K Display zones Engine speed Catalytic converter temperature Amplitude ratio Result of catalyst ageing test (Test OFF/Test ON/Cat B1 ok/Cat B1 nok) Specification Cat B1 ok Analysis 1100...1400 rpm min. 400.0 C 0.00...0.50 Read measured value block 99 xxxx rpm 1 Engine speed (idling speed) Coolant temperature Lambda controller upstream of catalytic converter Operating state of lambda control of lambda probe upstream of catalytic converter Specification ctrl. OFF or ctrl. ON Analysis -25.0...25.0 % 80...110 C page 01-44 page 01-40
01
For defined fault finding, the lambda control is switched off when display group 099 is selected under Initiate basic setting, or is switched on when selected under Read measured value block. The lambda control is automatically active again when function 04 Basic setting is quit.
01
What is displayed is the specified engine speed set by the engine control unit (value computed in control unit). A/C High = air conditioning demands high heating or cooling capacity A/C Low = air conditioning not switched on Notes on display zone 4:
------------
R h e ' $ e R ! d e G Yb ) H X RSc G FE1 V1 W1 Hb @ P1 I1 AF )1 @F Hb Tb T1 T T RB) PA IA A0 )C 0 B @A QS2 H1 H 3G ( 7@ 4QE 8@ 8H 5BC 1U 0S ) 2 ' & 9GD 6@ # ! % D c ` UEE $ # 2 F EB AEfE a` A 0 2
Self-Diagnosis
OCTAVIA
states
Engine idling
ext
ext
state
compressor
Specification or
state
or
Engine speed
Engine speed
idling
rpm
page
On models not fitted with air conditioning Compr. OFF is always displayed. Test signal from and to AC compressor.
If accelerator pedal is depressed suddenly, the readout in display zone 4 must jump from on to off for a few seconds (AC compressor switched off when vehicle accelerates).
-------------
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Edition 03.01 S00.5133.50.20 Driving Read measured value block Read measured value block Engine idling Engine Engine
OCTAVIA
engine
engine
n the
value
range
on
idling
Self-Diagnosis
valve angle
in
in
states
the
and
the
------------
-------------
01
01
------------
e XY Y X U i W Y g W Y g c f aa X Y c U X `X V h b T 7b IDa FA` ES C 8 @ @ 9 FbbR PU P`A`TU C`W GBS Ad HV A "2pT q ` ("c )T" ( ( ) ! ( #Y %) ' 50 3 & 1 ) " ! 4 ! # $( " "
Self-Diagnosis
OCTAVIA
4 x
Meaning
engine
Engine idling
xx.x %
xxxxx 4
Operating states
xxxxx
page 01-62
page 01-40
is set
the engine
-------------
OCTAVIA
Display group 060, engine speed control - Adapting electronic throttle system1)
Ignition on, engine not running Control unit in function 04 Initiate basic setting xx % 2 x Text 4
Self-Diagnosis
01
Analysis
10...90 %
90...10 %
1)
page 24-32.
Adaptation of the throttle valve control unit is performed with the ignition switched on.
If display group 060 is selected in function 04 Initiate basic setting, the engine control unit is adapted to the throttle valve control unit. This adaptation must always be performed if another throttle valve control unit (or complete different engine) or another engine control unit has been installed. If the voltage supply was interrupted (battery disconnected), it is also necessary to carry out adaptation page 24-28, Procedure after interruption of voltage supply.
xxx.x %
xxxxx 4
Operating states
Analysis
page 01-62
Engine speed
650...5700 rpm
01
Self-Diagnosis
OCTAVIA
Display group 062, engine speed control - Electronic throttle system Notes: The reason why the readout in display zone 1 rises as a percentage and the readout in display zone 2, in contrast, drops, is because of the contra-synchronism of the potentiometers (angle sensors) in the throttle valve control unit.
The readout displayed in display zone 3 must always be approximately twice as much as the readout in display zone 4.
Ignition on, engine not running
The engine control unit converts the voltage values of the accelerator pedal sensors into a percentage (related to 5 V). Supply voltage of 5 V equals 100 %.
The voltage tap of angle sensor 2 moves away from 5 V in the direction of 0 V. (The more the throttle valve is open, the less is the voltage; the percentage readout drops).
This means that the voltage tap of the one angle sensor moves in the direction of 5 V. (The more the throttle valve is open, the greater is the voltage; the percentage readout rises).
------------
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K in K Specification Analysis ------------Edition 03.01 S00.5133.50.20
OCTAVIA
Meaning of the digits in the 4-digit readout, display zone 2, switch for brake, clutch and CCS 1 1 1 1 Meaning
Self-Diagnosis
01
xxxx 4
Specification 0000
Analysis
0 km/h
0000
page 01-65
1)
01
Display group 070, exhaust reduction - Diagnosis of activated charcoal filter system
Engine idling in
Note:
TVV means tank vent valve (solenoid valve for activated charcoal filter system). Diagnosis can only be initiated once for each engine start. Note on display zone 2: The readout must not be greater than 5 % during the diagnosis.
Note:
Adaptation must always be performed if another EGR valve or engine control unit is installed.
C 6 4 6 C T Q 5 C1 H T 6 70000000 D0000 7 8 $ 3 C ' ( " 000( H H 1" 0" Q000 Q$H 00 0 () " " 10 C C4 3 (! () ) C C6 @ C CG 3 D4 E E D F ' ( C " P " I S ) 3 C3 C0B @# A" D 3! 3 BF 9)5 7 $% 8 ! ) ( ! 69 ( 4 ) ) 1 3 1 ' % $ ) C P " () ( # "5 H ! 0) ) ) 2) ) ) ! $ ) 0000 ) $ ) )
Self-Diagnosis
OCTAVIA
in
in
Specification
Analysis
<5
in
in
Specification A P
Analysis
OCTAVIA
Display group
Driving
# 2' 1 ) $ & & % 0 ( ' ' D B 4 5 4 A 5 4 9 8 6 3 6 #G 2'@ 1R )Q $F &I & %H 0B (! ' 'R !P4 C7 E E 5
Self-Diagnosis
01
gas
diagnosis
xxx mbar
Text 4
Syst. ok
Analysis
xxxxxxxx 4
Readiness code
Coolant temperature
Diagnosis status
80.0...110.0 C 00000000
Analysis
page 01-44
page 01-68
------------
-------------
01
------------
# $ " " ! !
Self-Diagnosis
OCTAVIA
of -digit
display
The readiness code is generated only if all readouts are 0 1 2 3 4 5 6 7 8 0 Diagnosis function Catalytic converter
Catalytic converter heater (no diagnosis at present/always 0) Activated charcoal filter system (tank vent system)
Air conditioning (no diagnosis at present/always 0) Lambda probes Lambda probe heater
-------------
OCTAVIA
24
Always switch off the ignition before disconnecting and re-connecting the battery otherwise the engine control unit may be damaged. Components marked with * are tested by selfdiagnosis page 01-6, Interrogating and erasing fault memory.
Components marked with ** can be tested with the final control diagnosis page 01-29. A voltage of at least 11.5 V is required for proper operation of the electrical components. Do not use any sealants containing silicone. Traces of silicone elements inducted by the engine, are not combusted in the engine and damage the lambda probe.
When conducting certain tests it is possible that a fault is detected by the control unit and is stored. For this reason, after completing all the tests and repair work, interrogate the fault memory and erase it, if necessary page 01-6, Interrogating and erasing fault memory. Safety precautions page 24-2. Rules for cleanliness page 24-3. Technical data page 24-3. Testing operating states of the engine page 01-45, display group 005.
24
Fuel preparation/injection
OCTAVIA
Safety measures
Note! The fuel system is pressurised! Place cleaning cloths around the connections before loosening hose connections or opening test connections. Then let the pressure out carefully by pulling off slowly. The following points should be observed in order to avoid injury to persons and/or destruction of the injection and ignition system: Do not touch or remove ignition leads while the engine is running or at start speed. Only remove or attach lines to the injection and ignition system and also the measuring device lines when the ignition is switched off. Please observe the following if it becomes necessary to use checking and testing equipment when undertaking a test drive: The checking and testing equipment are always to be fixed to the rear seat and also to be operated from there by a second person. If the checking and testing equipment were also operated from the front passenger seat then the person there could suffer injury from the airbag if a crash occurred. When the engine should be run at the starter speed without firing: For engines with engine identification characters AXP Kpull out the 4-pin connecting plug from the ignition transformer -arrow-
------------
K-------------
For all engines pull out the connecting plug on the injection valve -arrows-
OCTAVIA
24
Pay careful attention to the following 5 rules for cleanliness when carrying out work on the fuel supply and injection system: Thoroughly clean connection points and the surrounding area before disconnecting. Place removed parts down onto a clean surface and cover over. Do not use fluffing cloths! Carefully cover over or seal opened components if repairs are not carried out immediately. Install only clean parts: Do not remove replacement parts from their wrapping until just before installing. Do not use parts which have been stored unwrapped (e.g. in tool boxes etc.). If the system is opened: Avoid working with compressed air, if possible. Avoid moving the vehicle, if possible.
------------------------
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4 3 2 Nominal resistance Page 24-14
-------------
24
------------
intake t
or t
Fuel preparation/injection
connection
OCTAVIA
OCTAVIA
12 6 lug connection black for lambda probe and lambda probe heater 13
24
Engine fitting location: at inlet side of cylinder block page 24-7, item 14
valve
with
16 Lambda converter
with marking for ignition cables, do not mix up page 28-3, item 2
fitting location: lambda probe upstream of catalyst, in exhaust manifold; lambda probe downstream of catalyst, behind main catalytic converter
valve
activated charcoal filter: 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20
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4 3 2 Nominal resistance Page 24-14
-------------
24
------------
intake t
or t
Fuel preparation/injection
connection
control
OCTAVIA
OCTAVIA
10 - Knocking sensor 1 (G61) page 28-5 Position 4
Fuel preparation/injection 15 - Valve for the exhaust gas recycling (N18) with a potentiometer for exhaust gas recycling (G212) 16 - Hall sender (G40) page 28-5 Position 7 17 - Lambda probe before the catalytic converter (G39), 50 Nm, lambda probe after the catalytic converter (G130), 50 Nm Installed location: lambda probe before the catalytic converter in exhaust manifold, lambda probe after the catalytic converter behind the main catalytic converter 18 - Solenoid valve for the activated charcoal container (N80) activated charcoal container: 1.4/55 kW engine - mechanics; Rep. Gr. 20 19 - Ignition coils with power transformer (N70, N127, N291 and N292)
24
11 - Sender for the engine speed (G28) installed location: the cylinder block on the suction side page 24-7 Position 14 12 - 3-pin plug connector grey for the sender for the engine speed (G28) 13 - 6-pin plug connector black for the lambda probe and lambda probe heating 14 - Sender for the coolant temperature (G62) with coolant temperature indicator (G2) checking page 24-14
------------
-------------
24
OCTAVIA
1 - Plug
2 - 3 Nm
3 - Air filter disassembling and assembling page 24-13 4 - Cable duct clipped onto fuel rail
------------
-------------
5 - 10 Nm 6 - Fuel rail with injectors disassembling and assembling bottom part of intake manifold page 24-9
OCTAVIA
24
activated charcoal filter system 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20 connection black for throttle valve control unit (J338) contacts gold-plated
10 F
& ( 2) 6 5 # )% 4 !$ & &( ' 0 & 1 3 & ! " ' # 2 1
From 11 replace 12 to EGR valve 13 14 testing page 01-40
------------------------
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fitting location: in coat ignition not get into
-------------
------------
24
23
22
21
20
18
17
coolant t
of
clip
if
connection
of
in
of
of
off
of
ageing
30 F
28 Vacuum
27
24
34
33
32
31
Fuel
fitting location: in if
engine
oil
Engine
Engine
line
to
OCTAVIA
OCTAVIA
24
and
1-
control unit testing page 24-16 if replaced, adapt engine control unit page 24-32
replace if damaged
6 - 20 Nm -
2 - 10 Nm 3-
replace
replace
4 - Inlet connection
------------
-------------
24
10
------------
& ' 3 6 # & $ 5 4 # # & 2 $ 3 # 1 '% % ! '( ' & ) %# 0'" 1 ( $
Fuel Formation/Fuel Injection 11 I i
OCTAVIA
replace if damaged
testing intake manifold temperature sender page 01-43 specified resistance page 24-14, Fig. 2 testing intake manifold pressure sender page 01-42
12 I
13
-------------
OCTAVIA
u Y I I I Y S X I P c V V e G I R Y d y cx t u I X X S w y Q v s v wq v5 t s 0 B D % 4R 4 p p 7 p r V& efB aF`2gB d`xS#D( Xih9 a&Q3 GF``W8 YGFA# GFP(# I' R% X7 I6 QQS # QQq % Q# cFFuqIH3 cxb5 #C #S% # C4 BEA 21 %A ' 2( & U4 T@ A0 $ ) ( ! "
Fuel Formation/Fuel Injection
24
and
rail
3 4
rail
testing page desired resistance: ance increases ...6 engine operating ture)
------------
-------------
24
Fuel line white secure with spring strap clips ensure tightly installed from fuel filter: 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20 blue secure with spring strap clips pay attention to fitting location to fuel pump in fuel tank: 1.4 l/55 kW Engine - Mechanical Components; Repair Group 20
------------
OCTAVIA
replace if damaged
11 Fuel testing fuel pressure regulator and holding pressure page 24-19 acuum
12
-------------
r @ 7 ( ) 7 1 ) 7 ) ) 7 1 3 ' ) 1 3 5 8 A bX C b5 e#6 A Sp5 U5 ' i5 A U# f' VA T# U6 V h U U U e W#G6 ( P57 g( aHc( QG' ' aB !@ )7 31 (0 ('# (' 5 5 d2 09 6 6 b#@ V57 IX" U) U3A V@ U7 Y3 V( `) % $ WXQq3 W4 VQQ'35# U! S6G) TQaH35 ID RQ6865 G! G75 WaHG#26' PHH7 (( 3( E7 F&
Edition 03.01 S00.5133.50.20
OCTAVIA
Filter element
air
and
air
ensure
------------
-------------
24
24
------------
OCTAVIA
coolant
The chart is splitted to two temperature ranges: A - from 0...50 C B - from 50...105 C
Examples:
Connect multimeter for resistance measurement to contacts 3 + 4 of the coolant temperature sender. temperature
K Fi . 2
The chart is splitted to two temperature ranges: A - from 0...50 C B - from 50...105 C
Examples:
Connect multimeter for resistance measurement to contacts 1 + 2 of the intake manifold temperature sender.
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T x T U X q T s tV qx T r T T q U q T U T U x X q u s W s d u ar wr X Xv r X X T r r X X X T Y T X d W X T U r r X r x X r X T r T Tr x y r x r q X U X T r r X T T q T V u s u va r X x X q T X s c y w w T q x r T X T X W u wU TU VV XT T y raVV qV T V U rV T T r U T r syV s XV ryt Xt r u Svy AV F A Q T T T q U T q e cVVt byVyv b `vv VV f d b W s p wV wy T T T x T r eU cVy bq by `y i da s u s T X Y e cyvt b i ` i g f d W Saayt Ray AP A Gh D PU G F A F P G @ D B A G A QaaaVyVy Q 9 Ca C 8 8 6 5 3 0B 0aa #yv # ( " ! '$ V " ! 2P 14 )P &I % vV V VaE t HV EvC a7
Notes: T The contact numbers of the connector and the socket numbers of the test box V.A.G 1598/22 are identical. Use adapter cables from adapter cable set for connecting the testers to the test box. t t and
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OCTAVIA
24
24
------------
7 % 1 $ % & 2 % 5 8 9 1 2 9 1 & 2 % 5 8 % 2 1 % 1 2 7'0 64 %4) %0' 20 ( 2 4 4 $ ( & 5% 54 # ' ! " 3) 0 0 ' ' 0
Fuel Formation/Fuel Injection
OCTAVIA
control unit
Components of throttle valve control unit -J338-: throttle valve drive -G186-, angle sender 1 for throttle valve drive -G187- and angle sender 2 for throttle valve drive -G188-. Note:
If the throttle valve control unit is replaced, it is then essential to adapt the new control unit to the engine control unit page 24-32. and
Hand-held multimeter, e.g. V.A.G 1526 A Adapter cable set, e.g. V.A.G 1594 A
l Throttle valve must neither be damaged nor dirty. l Coolant temperature at least 80 C. l Battery voltage at least 11.5 V.
K-
If the voltage supply and cables of the throttle valve control unit are o.k.: Replace engine control unit page 24-29.
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OCTAVIA
Fuel preparation/injection
K-
K-
F H P I G 0 1 " 0 A E D 0" ( 0 % $ 4 0 1 0 0 1 " 0 '9 ' ! 9 9 @ A C B 0" (% 0$ %$ $% 4 0 1 0 0 1 " 0 ' ' !' 9 9 @ 0 $ 1 0 " 8 0' ( " 0 ( 1 0 ! 8 2 % 2 4 " " $% 7 $ 6 % 5 % 0 " % # 1 0 !&& " 3 2% $ "9 %$ % 1 0 # % $ " " ( ( " ' ' ! ' ' & ' & ' '' & ' '& )
24 jet injection and
and and torque wrench adapter cable set, e.g. V.A.G 1594 A digital potentiometer, e.g. V.A.G 1630 measuring glasses, e.g. V.A.G 1602 l the fuel pressure must be OK, check it page 24-19. remove the engine cover t e For e pull out the 4-pin connector -arrow- from the ignition transformer. t e For e pull out all ignition transformers using the extractor T10094. For all pull out the 4-pin connector from the sender of the coolant temperature (G62) -arrow-.
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24
OCTAVIA
K-
Connect digital potentiometer to contacts 3 + 4 of the connector and set the connected side to 15k.
K-
Detach vacuum hose from fuel pressure regulator -arrow-. Detach wiring loom of the injectors at fuel rail. Remove fuel rail complete with all injectors from camshaft housing (the fuel hoses remain connected) page 24-11.
K-
Hold a measuring vessel below the injector to be tested and unplug the connectors from the remaining injectors. Have a second person operate the starter. The injector must eject in a pulsating spray. Repeat the test at the other injectors. When doing this, ensure that only the injector being tested is connected. To conclude, inspect the injectors for leaks. Not more than 2 drops a minute must drip out.
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If the fuel loss is greater: Switch ignition off. Replace the faulty injector page 24-4, item 4.
OCTAVIA
Fuel Formation/Fuel Injection Install the injectors in the reverse order. Pay attention to the following points: Replace the O-rings at all the injectors and moisten lightly with clean engine oil.
24
K-
3 ! & ! " ' 1 4 3# 20 !0 !) $ 0! ' & ! & 0 ' ' ' ! $ " 1! # 1 (% 0 % ) #
Insert injectors vertically into the fuel rail and into the correct position, and secure with retaining clips. Place fuel rail with secured injectors into camshaft housing and press in evenly.
fuel
regulator and
The fuel pressure regulator regulates the fuel pressure in line with the intake manifold pressure.
The specification for this test depends on the operating pressure of the fuel pump. Fuel pump pressure is approx. 3.0 bar (0.3 MPa). t t and
Pressure measuring device, e.g. V.A.G 1318 Adapter, e.g. 1318/10 Adapter, e.g. 1318/11
Remove fuse 28 for fuel pump from the fuse holder. Remove engine trim panel.
Detach fuel feed line -1- and collect fuel which flows out with cloths.
Warning!
Fuel system is pressurized! Before slackening hose connections or opening test connections, place cleaning cloths around the connection point. Then, release pressure by detaching carefully.
------------
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$ $ $ $ ' # # ' $ $ $ ! # 8 ! # $ $ " ! ! ! U # ' $ " ! 9 ! ! 1 2 ' 9 $ $ 7 ) ) 5 9 8 2 E ! $ " 5 7 9 5 ) ) 5 $ T "$ "" B ! $ " $ $ !" 9 $ % 3 $ B ! ! B % $ 3 ! ! $ S R 5 ) 2 E # """ $ $! " 6 6 H P( ! I % F $ D B " # $ !@ 1 ' $ " $ ! 2" " $ 4 $ 7"" 9 5T C" C 5 @ 8 $ 8" " ! B ! 9 A #" # ! ' " "" $" $ $ @ "! ! ! ! ! @ ( $ 3 !" ! 2 $ 6 6 7 9" ) ) 5 @ 1 2 T $ " 3 "" 1 ""( " ! "" $ $ $ !3 0 ) Q "" '4 $ $G $# $ " & " 3" " "" "" $ $ $ % ! ( " " ( " 8 " ( " " " " " ""
-------------
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24
K-
K-
K-
Connect
At
not
to
to
OCTAVIA
0 ' 0 $ 9 $ A ' 0 9 (0 ' 9 1 ' ! 6 ' 0 4 9 9 1 0 C '0 C $ G 1 6 D 1 F 0 I ' 1 F C 0 1 1H G 1 1 E 8 ( '( ' 9 9 9 C P( @ 0 ' 9 D 0 9 A @(8 ' ((( H ( 0 0 $ 1 ( 8 ( ' @ 9 1 5 4 7( 6H ( (( (38 0 0( '( # # %(( )((( 2 1 & $ ! (((8 BB ( (" (( (
Before disconnecting the pressure measuring device, place cleaning cloth again around the loose hoses of the feed line. Note:
------------------------
OCTAVIA
KK-
24
24
B 1 % ) 2 2 17 0(9 & (@ "5 &4 (&3 8 &A % % ( & &6 " )5 !( )$5( $ ! $ '$ !$ # #
Fuel Formation/Fuel Injection
OCTAVIA
for
Notes:
The leak detection spray is inducted with the unmetered air as a result of the vacuum in the intake system. The leak detection spray reduces the ignition performance of the mixture. This results in a drop in engine speed and in a change in the lambda probe value. It is essential to observe the safety precautions stated on the can. and
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Engine leak detection spray G 001 800 A1 condition
l Coolant temperature at least 80 C Read measured value block 004, display zone 3.
Connect vehicle system tester V.A.G 1552. Start engine and select address word 01 Engine electronics page 01-4.
Select function 08 Read measured value block and display group 001.
00111111
K Check in display zone 2 whether the coolant temperature is more than 80 C. Observe lambda control in display zone 3 and engine speed in display zone 1.
Spray the parts of the intake system systematically with engine leak detection spray.
If the engine speed drops or if the lambda control value displayed becomes greater: End output and switch ignition off.
Inspect sprayed point of intake system for leaks and rectify any leak.
OCTAVIA
h W E hE h Q RI DF D W i D SW P I I c v i F d X q c c R w I W D i q q r U I I D r v E q D i I v F H I W D Y x X y e cE RE qF W Q D c wv i q I R v D I Uc R r D I D F t F 0 g 3 0 7 f D q I D I I F F D c w i E q D I c v F Q DI IR cv IR E Di I q c D D UI i Sc FH F I q D q U E q v F F F I I D r v E q D i I c v Fi H I W D c Y ` X y EE Dy c R q W i D c w I eh pR yi FF p0 pPS yr `S p y y p y H t g 7 gTT 6TT ) 6 3 0 f IF Ev qUTPU DGTU Q cTU D w i q I R v D I D FS e y y t F DR Ir Q I R D I c I X v FFG y x D DS I I E E D w v FTGSTTT HVP F F s R D I i D u I q H IG W D q r h I R Q IT9 qPU IU cP5 qP c R UU i U Fv p e gT2 6 75 g 6 1 7 @ f b I c D WU I Yi e0 di XTSSTTT F C QPSG QU I I I R I E D U WU YPi aUGT `I X0 F H F Bi AVTUV 0U9PT 0TVVS 7U 35 7 9t 9V5 3 9 0 7 6 0 6 7 @iTT @V5 ( 20 2U &TG # $ ) ' %$ #U2 S2S TG $P "I !1 ! "P2 ! US5 SUP SS5 PT5 P54 PS 4P2 8 S2 $
Test resistance heater, also cables to resistance 1...5 ) low Electrical Locations. l l Coolant l Battery Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
24
Kl
control
the
the
the
the test.
in converter
cable set,
a test in on the
be in
at least 11.5 V.
are not
are not
in the test:
and
at least
V.A.G
V.A.G
to eliminate any
is also not
3.
OCTAVIA
D m B G R # % ( & 2 x 8 G 1 8 G G 8 G 1 f A #( ( ) w 4 2 ( % ' 8 1 H G G 0 r 1 R R ) ( 2 % v 1& G t u # # 4 ' # ( 1 1 1 q ) E ' 45 # ' % 2 4 2 2 ( # % 0 $ 2 & ( 5 D I B B o ) ( ( # % % 1 0 H i & 2 D 7 l I H 9 B l 0 p ) ) & % D 7 l I m2 B 1 R ( D D o 7 l 8 8 l I 8 B 8 ) 2 2 4 2 E 4 '2 D D 7 l I m B I 0 f k' j$ A h h i! e i' x x# x xU y y$" r y y r "$ y 1 8 xUh x x ys$ $ y "S 5 w Y c r s v$ r g$ ux f' r f u f c Y ` aA a i e g g f1 fA r Y p f d c f iy h h"$ i h X # 7"$ 9 8 )A )$ A2 ' 44 ( '' % 2 ( 2 0 1 0 3A " 5 # ' ( 2 ' 1 & # # # # ( 2 ( ' W S S 1 R )U %x e E AA '' 'A & 2 ( & S VA T S $B $( # ( Q !0 )$ ) ( AA '# "" U % 2 ( ( A 0 1 0 3 AU$$A U! n 5 ( # ' # ( 2 1A"A E ($" # ( # & # ( ' D Ig G G G G G H G ) ` & (h d 5 ' 2 % 2 # # & 0 1 E & ) # % ( # ( ( ( ' ( y (Y t$a #Y #5 (2 '# (A '4 # ( 2 ' ( ( ' ' C # D 3 B )' )q # ) bq #5 q ) q %F$ A 2 & ( ( 5 u % 1# 7 9 8 )3b # #' (' ) 5% A"3"3 'Ua6 '' 4A3@ ( A 'A$ 3 % 2 ( 2 0 1 0 3" (' # #' (' A!"a #' #$""A@e ("" '2 &"6 %A F ' #" $" $F ' "' $"" $""$"3 ""$$"3 AP """P 3" "3 ""$U""$" ""$$ " "$
l l l
OCTAVIA
Kl
K-
control
Use
and
and
A t
24
24
------------
Fuel Formation/Fuel Injection
OCTAVIA
Conduct a road test in order to eliminate any residues on the lambda probe, and repeat the test.
If the specification in the display is also not achieved after a road test:
Test resistance of voltage supply for heater, and also cables to -Z29 (specified resistance 1...5 ) Current Flow Diagrams, Electrical Fault Finding, Fitting Locations.
K-
Separate the 4-pin plug connection to the lambda probe downstream of catalytic converter (G130) -arrow-.
K-
Set multimeter for voltage measurement and connect to contacts 3 + 4 of connector at wiring loom to control unit. Start engine and measure basic voltage Specification: 0.400...0.500 V Switch ignition off.
Test cable of lambda probe downstream of catalytic converter Current Flow Diagrams, Electrical Fault Finding, Fitting Locations. If the specification is achieved: -
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R B Q V R B Q b v V Y p Q B S X x V i R b i B Y Q b v R d Q p e q q A S S x V@ iV Q V i w Q V p Q V R B R d i S S G q Wb D V Y Q b R B p t V e q st D d Tt u B V p Q p R Q V R d Y R V RR q S S S S V V t V w U 9 ' 2 & ' ( 7 h h R B Q p B t Y R Y R S hA s h x iT QB Q Y p Q R V i cWR B Q Y R V p B x u x B V V t p i p V S U A yV YV Rf Rt B R B t V b b i V V c S S uG Bt X V u t u p B R c S U wV Bb Sq x RRd QR YtV pY Rrci VqS RFQ BcXp pWIV bw BQ t c q SVQ UtS Vx Yq Qred Brre wG VV bd Bi bt Vx SWBW sAW VdW RWr R Q t R R B V p R R B t Q U U V Vr b B b R ScT s ud BrV vU R' QXd Vyrr R5 Y R V R V V V R B V p R R B t Q SV AR SXc A U DWr h Vi VdrcT b6r B6 bcyy Rrc dR dr3 R Q dv drd V p St FWc Ic Sr q gr 2 3 g 2 ( 3 7 f Dcdrr a YX VX V b Q Eycc ew Frp S Dcd P V Y V R Q EWp `t Irrcrc S U S Dc @ B C E A IrW Irr G F 9)dW 8dc 'dd 'Xd 3H) 0 6' 3 2 ' 2 6c 3 & 0 3 ' 7tr 7drr) % )r "c5 !5 !d c 1W ) r ' Wp Xdc ( 5d rX1 4c $d rT 6d #Xc
4 C Fuel Formation/Fuel Injection C K est battery Kl l l l Battery such as l All electrical rear heater, must be l l Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
OCTAVIA
control unit
Select
must be
Start
est
control unit
cable set,
V.A.G
is
low
multimeter,
at least 11.5 V
at least 11.5 V.
must be
and
water
with air .
V.A.G
V.A.G
lectrical
2).
must be
------------
-------------
24
! 0 d ! ! a # ! ! ! a ! $ 1 1 ) ( ( ' 0 0 9 ! ! ! ! ! 1 1 ) % ( ' 5 0 ' R B B C Q C V B C I B I V C E 9 9 ! ! ! ! % 78 ! ! ! ! 9 ! ! ! ! ! ! ! ! ! ! ! g 6 a! ! ! ! ! %% !a ! !6 ! ! ! 66 a ! v u x x w s v w u6 x w u u u 6 t y i f f $ 9 68 ! 6 6 ! ! fs g f 8 8V 96 a ! 6 #6 e 96 !" !" 6 ! 6! ! 6886 ! % 8! h 8! !8 ! " ! ! 8 ! ! 14 ' 0h8 0h d d % ! B ! ! c8 c rU r " ! 3" 586 5 5 5 b % ` 9D 9E Q EP P 9 aS !hD D ! " ! ! ! Wh888 F6 Q6 S B S R T G C I B G Q F V C B q66 D p8868 8 f f i $ ! h" ! 8 6 ! 98 ! f! g f 8x 8 " 96 6 & ! 686 #! ! ! 88 E e 9ss ! ! s # ! 6! ! 6 ! h % 8H 86 !s ! " ! h ! ! 1 '88 06 06 d % ! #86 ! ! c c 1 1 ! 366 5 0 0 5 b % ` 9 98 A ! 9 a8 ! P ! " ! ! ! ! W F8 Q S B S R T G C I B G Q F V H C B D Y6 X8# P E A 1 0 @ 5 ! 6P 9 h ! ! ! 6 $ 7! ! ! & 68 ! & 1 6 )P 46 (D 58 ' 5 3 2 0 % !6h8 !P 7 " D ! ! ## U 6 P 68 888D8E UDE 8 68 6 8
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24
Procedure
Procedure in
and
OCTAVIA
) " " " 3 4 ) 5 " ( & ) % 1 0 ) ) q 3 5 ) ) 4 ) # F F r $ 1 ) " " ) # " ) " 1 v y x d w u q 3 F F t r ' ' ' ' 1 1 q q 5 ) F F r 6 $ 1 !) i! h Y Y g d d g e X b p W V U P S R H G & ) ) 1 '! 1 0 500 5 3 ' ) F $ 0!00 0 'F2 ' &9 501 0 "1 )0F 0 '0 00 @ $0 )! 0 " ) 0' " # " " ) E ! " E D ) ! 5 ) 59! ) # ) " ) ) ) Y 6!! B & 5 ! " ) ) ! 4 3 0 @ 3 5a 5 5 " ) ) " 8 8 ) 9I s &!8 a! Y ` 4 ) ) ) ) 7 " $fc %ca $ & ) T 4 Q ) 4 ) 7 5 " 5 # ) 6 6 3 # #" " ) 4 " ! ( # & 8! ) $ 2 1 0 !! ! " $ ' % $ 8! C ! )!! # #! "! ! & ) 8 A ! !& ! !! ! ! ! !!!
Fuel Formation/Fuel Injection K t
OCTAVIA
------------
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24
a % H H 4 Q Q Q Q f f H ( & 4 #" " I f w w @ B @ w @ y w y @ v B u D q r q s r q s h g i 6 ) f Q f T 3 $ ) ) I 5 f T $ 6 ) & ! 5 f T ! x & & & ! ) ( S c $e$ !e$ & 4( 3( 5 d$( H 6$ D AC w A ! ) a $$DAC & ! ) & 1 " # 7 H S ` 1 X Y & ! G P ! ) W P T S ( )( ! ( ( # P T V H 6 6pp e ! ) ! (R (# " ) ! I Q P I H # ! ) ( ( ( " (( ( ) G " 2 (((( (F ! 2 ( " E 9 9 B ! 7 (( ( )( ( ( ! & ! (( " " ! 6 )& !($( ! F $ ( 1 3 " % ) T T & $$ !US 5 ((T T $ P y$ 0 4(T($ 3G5( 56(( 5Q$ 'T 1f d (( ( # ! & #(P( ") W 2$(F 8 (C @ ($(A & D (( ( ((( ( (( G (( (C ( (( $ ( ( (
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24
K-
Notes:
If the code displayed does not correcpond to the vehicle, or if the control unit has been replaced, it is then necessary to code the control unit as follows.
control unit
and
OCTAVIA
5 1 4 3 4 3 2 3 E A 6 9 5 5 5 A 3 A A 6 5 Q6 ! 1 5 3 4 3 E 3 "3 4 65 P 6 6 5 5 5 5 ! A r A A x G 6 5 5 A 3 3 4 3 3 E 4 3 4 3 3 6 6 5 5 5 2 3 G 0 u P 6 9 w v 5 5 5 Q 1 4 r 2 E 3 " tb 0E 97 07 s % q P `7 ' a 5 56 5 5 5 1 26 4 r 2 E 3 "D " q P$ P ' ) 7 7 G 0 u 9 w v 5 5 5 Q 1 4 r 2 E 3 " t" 04 94 07 sb % q P `4 ' ' 7 7 5 5 5 4 r 2 " E 3 P q ' 7 7 p7 e D W f d i7 i" i g g c T hE V4 h U W R 5 $7 ! 1 h 3 3 4 3 6 I5" ! E H3 6 5`"4 4Ay4 3 "1 !$" 23 33 4 E E3 36 4E 3 I3 P$ ! DA4 b 5 P3 P5 94 63 !DH 1P 3 I H 5 3w 37 E 4 3 47 " 4 3 4 3 E F 62 @ G 6 7 0 572 $"" 4 BV73 06 27' A"G 3a 4) q 7 7 7 3 2 3 '" $ 77 9 ' 7 C4 $ 5" a 57 1$7" 4Y DQa "7) S' 3(7 "$( 3QF 49 37 " 2 1a 6D3 68DY 6"84 6"3 0 $" $T Da4 XY Q" Y !! V DU " " (3 (43 &@)6 %"76 #Y )4 '"74 bE ` " P 3 E 9 B G
or Fuel Formation/Fuel Injection K K K The Motronic control unit does not use the code entered and which appears in the display until after the ignition has been switched off once for at least 15 s. Incorrect coding results in: Notes: Traction control system on FWD vehicles not operating (TCS/ASR warning light on) Functions not being performed (lambda control, actuation of activated charcoal filter system, etc.) Storage of non-existant faults in fault memory Increased emission levels Increased fuel consumption Vehicle performance problems (jerky gear changes, load change jolts etc.) Connect r n on t enter to
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OCTAVIA
24
24
------------
6 ( ) 6 ( # ) " 5 2 4$' 3$ "1$ " ) % ) 1 1 ! % # " ) ( " ( ) 2" 2' $ ' '& 0 '&$
Fuel Formation/Fuel Injection
OCTAVIA
As a result of the adaptation, the engine control unit learns various positions of the throttle valve when the ignition is switched on and the engine is not running. These positions are stored in the engine control unit. The feedback signals of the throttle valve position are provided by the two angle sensors for the throttle valve drive. Adaptation must be performed if:
the throttle valve control unit has been replaced the engine control unit has been replaced
another throttle valve control unit has been installed as a result of installing a different engine. and
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
l There must not be any fault stored in the fault memory page 01-6, Interrogating fault memory. l Battery voltage at least 11.5 V.
l If vehicle is equipped with air conditioning, this system must be switched off. l All electrical components such as lights and rear window heater, must be switched off. l Throttle valve control unit must be in idle speed position. l Throttle valve must not be dirty.
l Coolant temperature at least 5...80 C Read measured value block 004, display zone 3.
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OCTAVIA
0 3 2 3 2 1 ) 4 D 3 D @ D 3 8 1 2 H X 4 4 4 4 4 22 3 @ 1 2 2 3 5 5 F 6 S 4 4 #5 2 3 @ 3 @ 3 D D 4 $ 54 5 4 4 4 2 3 T 5 3 V W $ H 2 D V W $ 4 4 2 3 @ Q 2 2 3 @ B 5 ) 4 4 2 3 @ Q 2 2 3 @ T S 5 ) U 4 4 2 2 3 @ Q 2 2 B 5 S 5 4 F 4 R 3 3 2 3 @ ! ! 4 # 1 2 3 3 ! Q 5C 5 45 @ 2 # 3# ! 1 2 @ I H $ 4 @ D 3 1 @ 6 5 6 G 43 4C! 4 2! 1 23 ! 2! 2 3 2 D T P 5 9 2 F B 6 ) 4C! #2 AAE a 1!a @! 2# 3 7 2 ! 1 2 & 67 8 & 6 B3 4C 4 0b 3B d !! 2 !@ 2# 3C 2 ! 1 0 5DF 5E 5 5C# ) #c # #@ ! CC C C ! ! ! ! f 'H '& %9C) $C "#4 ( &C C2 1 ' 6 G U e Ee2
Fuel Formation/Fuel Injection
24
Connect
on
enter
been
to
Notes:
If the basic setting is aborted by the engine control unit, this may be for the following reasons: the throttle valve is not able to reach the mechanical idle speed stop because of dirt, e.g. oil carbon deposits, or because of a mechanical fault. the battery voltage is too low. the throttle valve control unit or the cable connection is faulty, test page 24-16.
After an aborted basic setting, the fault is stored in the fault memory. The next time the ignition is switched on, the basic setting is automatically repeated.
------------
-------------
X W U x U r s s w U r U U U s f D U U Y T T B X rs W U U D U U Y r s D U s r r f D w Tf T X W D r s U D Y s W U U s T T W r b R tes X X W s Y s W Wu sT U x p U D T Vr r D U D r D U U U U W q r D r D r b U D r W G T X Uw Ds r U ww U sf U Y W U D U r r w eD cD C T T G Q br YU rSet S D r D U r b r w U f r tf b fw D E U r D G Qe Q I H F C SW D UU U w p Y D D r U D D W VeS T T T UV W r w D r U U Y U s U w r Teee T T Y D b G Ws Yg xw re sp WV X D U w W U p W U U Ts Ta C T Ve AVSS ) 5 ( ) 0 6 ) 9 h S W b r W b D U r F Xf Xee UT bW Wb YSw De Ut xfe W U r U D f W s D T q v XS U W s x U w Ya D W Y U f f eVVSt p He X U U D Bt q ts UfaeSe XS UeaSt YSee bVT rSSe sP U U s D U Y D Y r U U D U U Y f TFS T T USt b W D p i 5 6a i 5 0 6 ) 9 h d b U U Y W G geSeS HVt F T R Xu U Y W U D b GSf ce Qf FVS T B D E GVS Qef QVat Ie Hf F C ASeV4` @8V )8e )eu 6f 2f 64 8w 88 ( 2 0 )4 6 5 ) 5 6 9) 9yt ' 1f e " eV`SS31 ee &41 e $4 #1 e3 7VV ! %f #1fe aeS P4VSVS af fee Saf af
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24
The right front wheel must not be rotated during this step.
Note:
l Battery
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C
the
est
test l
test
cable set,
additional
V.A.G
wheel.
at
test l
at least 11.5 V.
V.A.G
is
and
V.A.G
as the
to
V.A.G
memory.
short
to the a e
or
the slows
OCTAVIA
OCTAVIA
K-
D 7 # & 3 C1 A 7% ## A 7 ) # ( & 7 5 # # ) & # 1$ 1 @%) @1 3 B @ % D 7 # & " # # # 2 E 3 @ C# A1 7$ A 79 )%9 #E9 ( & 7 5 # # ) & # 2 1# 1 1 @# 32 B% %" %) @ %2 % 5% #1 ( " # $ ) # 3% 6 79 (1 )%8 7 ( $ ) 38 6 5%2 42 #2% #% )1 &1 2# ) ( # ( 2 ) " & $ ) # 3# 31 ! % 1 0' '%
24
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Refer to the appropriate current flow diagrams to determine which control units are connected to the drive databus (CAN; Controller Area Network). Check the plug connections of all the connected control units to ensure they are tight. Connect vehicle system tester V.A.G 1552 and enter function 00 Automatic test sequence. Before testing the communication line, determine whether there is any operational fault at the connected control units. t t and Test box V.A.G 1598/21 Hand-held multimeter, e.g. V.A.G 1526 A Adapter cable set, e.g. V.A.G 1594 l A fault has been detected at the databus by the self-diagnosis. Connect test box V.A.G 1598/21 -1- to the wiring loom of the ABS control unit -2-. Test terminating resistance in engine control unit. Measure resistance between sockets 10 + 11 of test box. Specification: 60...72 k. not Replace engine control unit page 24-29. - Test databus Electrical System; Repair Group 90.
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OCTAVIA
Ignition System
28
Do not disconnect and connect the battery unless the ignition is switched off otherwise the engine control unit may be damaged. The engine control unit is equipped with selfdiagnosis.
This section deals specifically only with the components related to the ignition system. For the other components of the fuel injection and ignition system from page 24-4.
Components marked with * are tested by the self-diagnosis page 01-6, Interrogating and erasing fault memory. A voltage of at least 11.5 V is required for proper operation of the electrical components.
When conducting certain tests, it is possible that the control unit will detect and store a fault. For this reason, after completing all the tests and repair work, interrogate the fault memories and erase if necessary page 01-6, Interrogating and erasing fault memory.
Before commencing repairs and fault finding, interrogate fault memory page 01-6, Interrogating and erasing fault memory.
If the engine starts only for a short time and then cuts out again after conducting fault finding, repairs or tests of components, the reason for this may be that the immobiliser is inhibiting the engine control unit. In such a case, it is necessary to interrogate the fault memory and to adapt the control unit page 24-32.
Safety precautions page 28-1. Test data, spark plugs Inspection and Maintenance.
Safety precautions
Pay attention to the following points in order to avoid injuries to persons and/or damage to the fuel injection and ignition system: Do not touch or disconnect ignition cables when the engine is running or operating at starting speed. Do not disconnect or connect cables of the fuel injection and ignition system - also not cables of test equipment - unless the ignition is switched off.
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Please observe the following if it becomes necessary to use checking and testing equipment when undertaking a test drive: The checking and testing equipment are always to be fixed to the rear seat and also to be operated from there by a second person. If the checking and testing equipment were also operated from the front passenger seat then the person there could suffer injury from the airbag if a crash occurred. When the engine should be run at the starter speed without firing: For engines with engine identification characters AXP Kpull out the 4-pin connecting plug from the ignition transformer -arrow-.
For engines with engine identification characters BCA pull out all ignition coils using extractor T10094.
For all engines Kpull out the connecting plug on the injection valve -arrows-
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Removing and installing parts of the engines with engine identification characters AXP
3 - Connector black, 4-pin for the ignition transformer (N152)
1 - Ignition lead with shielded plug and spark-plug resistance 4.8 .. 7.2 k
2 - Ignition transformer (N152) with identification for the ignition leads: A = Cylinder 1 B = Cylinder 2 C = Cylinder 3 D = Cylinder 4 page 28-4, Figure 1 checking Installed location page 24-5
4 - 10 Nm 5 - Connector black, 2-pin for the knocking sensor 1 (G61) contacts gold-plated 6 - Knocking sensor 1 (G61)* contact from the sensor and the connector, gold-plated installed location page 24-4 7 - 20 Nm the tightening torque has an influence on the function of the knocking sensor 8 - Connector black, 3-pin for the hall sender (G40) 9 - Hall sender (G40)* Page 28-6 checking installed location page 24-5 10 - O-ring replace when damaged 11 - Spark plug, 20 to 30 Nm removing and installing using a special spark plug wrench (e.g. 3122 B) Injection type and change interval and Maintenance 12 - Ignition cable strip holder
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The ignition system
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the
check the secondary resistances on the terminal between cylinders 1 + 4 and cylinders 2+3 Nominal value 4.0 .. 6.0 k (at 20 C).
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The ignition system
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contact from the sensor and the connector, gold-plated installed location page 24-5.2
the tightening torque has an influence on the function of the knocking sensor
black, 4-pin
20 to removing and installing using a special spark plug wrench (e.g. 3122 B) type and change interval Injection and Maintenance
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The ignition system
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the
ing
testing
K-
pull out the 3-pin plug from the hall sender -arrowsconnect up the hand multimeter for voltage measurement to contact 1 (plus) and 3 (earth) of the plug. switch on the ignition: Nominal value: at least 4.5 volts switch off the ignition:
K-
check the cable connections to the sender according to the current flow plan Current flow plans, Fault Detection Electrics, Installed Locations
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