1. Manuals
  2. Brands
  3. Skoda Manuals
  4. Automobile
  5. OCTAVIA
  6. Workshop manual

Skoda Octavia Workshop Manual

1.8 ltr./92 kw engine- motronic fuel injection and ignition system
Hide thumbs Also See for Octavia:
Table of Contents

Advertisement

Quick Links

See also: Workshop Manual , Owner's Manual
Service
Workshop Manual
OCTAVIA
1.8 ltr./92 kW Engine - Motronic Fuel
Injection and Ignition System
Service Department. Technical Information
S00.5107.50.20
Edition 08.96

Advertisement

Table of Contents
loading

Related Manuals for Skoda Octavia

Summary of Contents for Skoda Octavia

  • Page 1 Service Workshop Manual OCTAVIA 1.8 ltr./92 kW Engine - Motronic Fuel Injection and Ignition System Service Department. Technical Information S00.5107.50.20 Edition 08.96...
  • Page 2 The Workshop Manual is intended only for use within the ŠKODA Organisation; it is not permitted to pass it on to third parties. © 1996 ŠKODA, automobilová a.s. Printed in Czech Republic...
  • Page 3 Service List of Supplements to Workshop Manual Edition: 10.99 OCTAVIA 1.8-ltr./92 kW Engine, Motronic Fuel Injection and Ignition System Replaces List of Supplements - Edition: 03.98 Subject Edition Article Number Supple- ment 08.96 Basic Edition of Workshop Manual S00.5107.50.20 11.96 Supplement to Repair Groups 01, 24 and 28 S00.5107.51.20...

  • Page 5: Table Of Contents

    OCTAVIA Service Contents Self-Diagnosis Page Self-diagnosis ..........................01-1 Features of self-diagnosis ......................01-1 Technical data of self-diagnosis ....................01-2 Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit .. 01-3 Interrogating and erasing fault memory ..................01-5 Fault table ..........................
  • Page 6 Service OCTAVIA ..................7 ..................ä ä ................................Testing lambda control ....................... 24-42.3 ..........................................................................................Replacing, coding and adapting engine control unit .............. 24-48 ................................................................................. Testing additional signals ......................24-55 ............................

  • Page 7: Self-Diagnosis

    OCTAVIA Self-Diagnosis Self-diagnosis Note: The self-diagnosis monitors only a part of the fuel injection and ignition system. Features of self-diagnosis The Motronic control unit (J220) for the fuel in- jection and ignition system is equipped with a fault memory. The fault memory is designed as a permanent memory and a volatile memory.

  • Page 8: Technical Data Of Self-Diagnosis

    OCTAVIA Self-Diagnosis 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 engine electronics control unit ⇒ page 01-3. Functions available when using the vehicle system tester V.A.G 1552...

  • Page 9: Connecting Vehicle System Tester V.a.g 1552 And Selecting Engine Electronics Control Unit

    OCTAVIA Self-Diagnosis 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 Test conditions l Battery voltage at least 11.5 V l Fuses 10, 12, 29 and 32 o.k.
  • Page 10 OCTAVIA Self-Diagnosis ⇒ Note: Operate the vehicle system tester according to the readout which appears on the display. → ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ä ä ä ⇒ Notes: ♦ If the control unit version displayed does not match the vehicle, replace control unit ⇒...
  • Page 11 OCTAVIA Self-Diagnosis increased fuel consumption increased emission levels storage of non-existent faults in the fault memory ♦ Functions not being performed (lambda con- trol, actuation of activated charcoal filter sys- tem, etc.) ♦ Reduction in gearbox life If the coding does not match the corresponding version in the vehicle: Check coding of control unit ⇒...

  • Page 12: Fault Table

    OCTAVIA Self-Diagnosis Test of vehicle systems HELP K Readout in display: Select function XX Press 06 to select the function „End data transfer“ and confirm the entry with the key If one or several faults are stored: Fault number: 00515 K Readout of fault number in display, e.g.:...
  • Page 13 OCTAVIA Self-Diagnosis ♦ Coolant temperature should rise to more than 80 °C. ♦ Once this temperature is reached, the operating states of idling part throttle full throttle overrun should be achieved several times. ♦ Engine speed should be increased to more than 3500 rpm at full throttle.
  • Page 14 OCTAVIA Self-Diagnosis Press the keys 0 and 5 for the function „Erase fault memory“ and confirm the entry with the key Q. Test of vehicle systems K Readout in display: → Fault memory is erased! Note: If you switched off the ignition between „Interro- gating fault memory“...
  • Page 15 OCTAVIA Self-Diagnosis Fault Notes: ♦ If ”see literature” appears in the display, refer to the ♦ Explanations on fault types (e.g. ”open/short circuit to fault table for the text belonging to the fault code. earth”): ⇒ Operating instructions of the vehicle system tester ♦...
  • Page 16 OCTAVIA Self-Diagnosis of fault voltage Signal too large ♦ Supply voltage greater ♦ Engine control unit de- - Test voltage. than 16 V stroyed ♦ Overvoltage caused by - Read measured value jump-starting block, display group 003, ♦ Alternator faulty display block 2 ⇒...
  • Page 17 OCTAVIA Self-Diagnosis Possible of fault Possible adaptation Adaptation limit (add) ex- ♦ Fuel system pressure too ♦ Vehicle may jerk - Refuel vehicle, test fuel ceeded pressure regulator and holding pressure ⇒ page 24-27. Adaptation limit (mul) ex- ♦ Incorrect signal from air ♦...
  • Page 18 OCTAVIA Self-Diagnosis of fault Signal too ♦ ♦ ⇒ ⇒ ♦ ♦ ♦ ♦ ♦ Signal ⇒ Signal too ♦ ♦ ⇒ ⇒ ♦ ♦ ♦ ♦ ♦ Signal ⇒ ♦ ♦ ⇒ ⇒ ♦ ♦ ing to ⇒ ♦...
  • Page 19 OCTAVIA Self-Diagnosis of fault fault 01119 signal Open/short circuit to posi- ♦ Open circuit or short cir- ♦ Slightly greater, brief varia- - Test cable connection to tive cuit to positive in signal tions in engine speed multifunction switch -F125...
  • Page 20 OCTAVIA Self-Diagnosis effects Control limit not reached ♦ Throttle valve jamming ♦ Increased idling speed - Read measured value ♦ Positioner mechanism block, display group 23 jamming ⇒ page 01-63. Control limit exceeded ♦ Fault (open/short circuit to ♦ Load change jolt when ac-...
  • Page 21 OCTAVIA Self-Diagnosis Fault fault of fault Signal ♦ ♦ ♦ ⇒ ♦ ♦ ♦ ♦ Solenoid valve 1 vated ♦ ♦ ⇒ ♦ ♦ ♦ ⇒ ♦ ♦ ♦ ⇒ ♦ ♦ Edition 10.99 ------------ ------------ S00.5107.53.20...
  • Page 22 OCTAVIA Self-Diagnosis of fault Short circuit to earth ♦ Short circuit to earth in ca- ♦ Irregular engine running, - Test injectors ble connection from injec- engine may cut out ⇒ page 24-29. tor to engine control unit ♦ Injector faulty Short circuit to positive ♦...
  • Page 23 OCTAVIA Self-Diagnosis of fault Open/short circuit to ♦ Open circuit in open engine open circuit in ♦ short circuit to not run ing or short circuit short circuit to ♦ ⇒ engine control gine continues running unit ignition high ♦...
  • Page 24 OCTAVIA Self-Diagnosis effects Signal too small ♦ Unmetered air between air ♦ Emergency running (sub- - Determine leakage and mass meter -G70 and en- stitute value from throttle rectify. gine valve angle and engine - Read measured value ♦ Voltage supply to -G70...
  • Page 25 OCTAVIA Self-Diagnosis of fault Signal too ♦ ♦ ⇒ ♦ ⇒ ♦ Signal ⇒ Signal too ♦ ♦ ⇒ ♦ ⇒ ♦ ♦ Signal ⇒ Edition 10.99 ------------ ------------ S00.5107.53.20...
  • Page 26 OCTAVIA Self-Diagnosis of fault Implausible signal ♦ Coolant temperature ♦ Cold start problems at - Read measured value sender -G62 supplies im- very low temperatures block, display group 003 plausible signal because ♦ Poor driving characteris- ⇒ page 01-46. of loose contact or corro- tics in warming-up phase - Test -G62 ⇒...
  • Page 27 OCTAVIA Self-Diagnosis of fault Signal too large ♦ ♦ ♦ ⇒ engine ♦ ♦ ⇒ tion ♦ ♦ ♦ Signal in engine engine trol ⇒ Note on fault code 16501 and 16502: As soon as one of the faults is detected, the control unit uses a substitute value from the model temperature pat- tern stored in the control unit.
  • Page 28 OCTAVIA Self-Diagnosis Fault fault code cause of fault effects Electric fault in circuit ♦ Open circuit in wiring or ♦ Jerky acceleration - Rectify short circuit or short circuit to positive ♦ Load change jolts when open circuit in wiring.
  • Page 29 OCTAVIA Self-Diagnosis of fault Electrical fault in circuit ♦ Corrosion caused by mois- ♦ Lambda closed-loop con- - Rectify short circuit or ture in plug connection of trol switches to open-loop open circuit in wiring. probe heater -Z19 or ⇒ Current Flow Diagrams,...
  • Page 30 OCTAVIA Self-Diagnosis of fault No activity ♦ Lambda probe faulty ♦ Increased fuel consump- - Read measured value (dirty) tion block, display group 021 ♦ Emission levels not o.k. ⇒ page 01-62. ♦ Open circuit in wiring be- ♦ Carbon deposits on spark...
  • Page 31 OCTAVIA Self-Diagnosis of fault Signal too ♦ ♦ ⇒ ♦ ♦ ⇒ ♦ Signal ⇒ Signal too ♦ ♦ ♦ ♦ ⇒ Signal too ♦ ♦ ♦ ♦ ⇒ Signal too ♦ ♦ ♦ ♦ ⇒ Signal too ♦ ♦...
  • Page 32 OCTAVIA Self-Diagnosis of fault signal Implausible signal ♦ ♦ ⇒ ♦ ♦ ⇒ page ♦ ♦ panel engine ⇒ signal ♦ ♦ ⇒ page signal engine ♦ ♦ ⇒ page ------------ ------------ Edition 10.99 S00.5107.53.20...
  • Page 33 OCTAVIA Self-Diagnosis of fault Control limit not reached ♦ Poor fuel quality (less than ♦ High fuel consumption - Refuel with fuel of at least 95 RON) 95 RON. ♦ Abnormal engine running ♦ Poor performance - Rectify cause for abnormal noises (ancillaries loose) engine running noises.
  • Page 34 OCTAVIA Self-Diagnosis fault of fault Idling Does not close/open ♦ Throttle valve sticking ♦ Load change jolt when ac- - Test -F60 ⇒ page 24-16. circuit ♦ -F60 faulty celerator released ♦ Setting of throttle cable ♦ Idling speed not within - Set accelerator cable.
  • Page 35 OCTAVIA Self-Diagnosis Possible of fault Possible Lower limit reached ♦ Unmetered air upstream ♦ High idling speed - Eliminate unmetered air. of throttle valve control unit Upper limit reached ♦ Intake system blocked ♦ No power - Inspect intake system.
  • Page 36 OCTAVIA Self-Diagnosis Possible of fault Possible ä Open circuit ♦ Open circuit in cable con- ♦ Poor acceleration - Test -N156 nection between intake ⇒ page 24-66. manifold changeover valve -N156 and engine control unit ♦ Voltage supply for -N156 faulty ♦...
  • Page 37 OCTAVIA Self-Diagnosis Possible cause of fault Possible effects Open circuit ♦ Open circuit in circuit in ♦ tween ment ⇒ unit binder ⇒ ♦ ♦ ♦ ♦ meter ⇒ ♦ Open circuit in unit ⇒ ♦ dirty ♦ ♦ unit ♦...
  • Page 38 OCTAVIA Self-Diagnosis of fault unit Undervoltage in basic set- ♦ Voltage below 10 V during - Test voltage, read meas- ting basic setting ured value block, display group 003, display block 2 ⇒ page 01-46. unit Lower stop is not reached ♦...
  • Page 39 OCTAVIA Self-Diagnosis of fault oltage Voltage too small ♦ Battery was disconnected ♦ Learned values in engine - Test voltage supply for en- ♦ Permanent voltage supply control unit are lost gine control unit at control unit was discon- ⇒ page 24-25.
  • Page 40 OCTAVIA Self-Diagnosis of fault ä ♦ No ♦ ⇒ ♦ ⇒ ä ♦ ♦ ♦ No ⇒ ♦ ⇒ ⇒ ------------ ------------ Edition 10.99 S00.5107.53.20...

  • Page 41: Final Control Diagnosis

    OCTAVIA Self-Diagnosis Final control diagnosis With final control diagnosis the following com- ponents are actuated in the order stated: 1. Injector cyl. 1 -N30 2. Injector cyl. 2 -N31 3. Injector cyl. 3 -N32 4. Injector cyl. 4 -N33 5. Solenoid valve 1 for activated charcoal fil- ter -N80 Models ä...
  • Page 42 OCTAVIA Self-Diagnosis Notes: ♦ Final control diagnosis can only be carried out when the engine is not running and the ignition is switched on. ♦ Final control diagnosis is aborted if the en- gine is started or if an engine speed pulse is detected.
  • Page 43 OCTAVIA Self-Diagnosis The ignition should be switched on when carry- ing out this step (⇒ page 01-3, Connecting ve- hicle system tester and selecting control unit for engine electronics). K Readout in display: Test of vehicle systems HELP Select function XX Press the keys 0 and 3 for the function „Fi-...
  • Page 44 OCTAVIA Self-Diagnosis ä diagnosis of intake K Readout in display: Final control diagnosis → Intake manifold changeover valve -N156 K Installation position of intake manifold change- over valve -N156 The intake manifold changeover valve should If the valve is not actuated (does not click), test intake manifold changeover valve -N156 ⇒...
  • Page 45 OCTAVIA Self-Diagnosis All models Final control diagnosis of camshaft adjust- ment: Final control diagnosis K Readout in display: → Camshaft adjustment 1 This valve continues to be actuated (clicks) un- til final control diagnosis is ended by pressing the → key.

  • Page 46: Reading Measured Value Block

    OCTAVIA Self-Diagnosis Measured value blocks Reading measured value block Special tools, testers and aids required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Test conditions l Coolant temperature at least 80 °C l Electrical components switched off (radiator...
  • Page 47 OCTAVIA Self-Diagnosis Test of vehicle systems HELP Select function XX the function value value HELP Note: Display group number 001 is an example in or- der to present the sequence. value → → Test of vehicle systems HELP Select function XX...
  • Page 48 OCTAVIA Self-Diagnosis Designation Designation Read measured value block 00 1 = Coolant temperature Basic function 1 2 3 4 5 6 7 8 9 10 2 = Engine load 3 = Engine speed 4 = Battery voltage 5 = Throttle valve angle...
  • Page 49 OCTAVIA Self-Diagnosis Designation Read measured value block 4 1 = Throttle valve angle Idling speed 2 = Idling air mass learned (automatic gearbox not in gear) stabilisation 3 = Idling air mass learned (gear of automatic gearbox engaged) 4 = Operating state:...
  • Page 50 OCTAVIA Self-Diagnosis Designation Read measured value block 10 1 = On/off ratio of solenoid valve 1 for activated charcoal filter -N80 Tank breather 2 = Lambda correction factor with active tank breather 3 = Filling level of activated charcoal filter -N80...
  • Page 51 OCTAVIA Self-Diagnosis Designation Read measured value block 17 1 = Engine speed Catalytic con- 2 = Engine load verter heating 3 = Energy balance for Cat heating 4 = Ignition angle Read measured value block 18 1 = Engine speed...
  • Page 52 OCTAVIA Self-Diagnosis Designation ä Read measured value block 1 = Operating state: Camshaft ad- Idling justment con- trol Part throttle Full throttle Overrun Enrichment 2 = Hall sender -G40 (°CRA) 3 = Control: Camshaft adjustment 4 = Active camshaft adjustment angle in °CRA ä...
  • Page 53 OCTAVIA Self-Diagnosis Designation ä Read measured value block 1 = Engine speed (rpm) Camshaft ad- 2 = Engine load (injection time for each crankshaft revolution in ms) justment con- trol 3 = Control: Camshaft adjustment 4 = Active camshaft adjustment angle in °CRA ä...
  • Page 54 OCTAVIA Self-Diagnosis Designation Read measured value block 1 = Throttle valve potentiometer voltage Adaptation of 2 = Throttle valve positioner potentiometer voltage throttle valve control unit 3 = Operating state: idling/part throttle 4 = Adaptation status: Adaptation in progress Adaptation o.k.
  • Page 55 OCTAVIA Self-Diagnosis Display group 000 to 007 Display group 000 at idling speed (engine warm, coolant temperature not below +80 °C) Display Specified readout Corresponds to Designation block measured value 170...204 80...105 °C Coolant temperature (requirement for basic setting) 20...50 1.0...2.5 ms...
  • Page 56 OCTAVIA Self-Diagnosis Test table display group 000 Display block Readout on V.A.G 1552 Cause of fault Rectifying fault ♦ ⇒ ♦ ♦ ⇒ ♦ ♦ ♦ ♦ ♦ ⇒ ♦ ⇒ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ⇒ ♦...
  • Page 57 OCTAVIA Self-Diagnosis field 1552 Cause of fault less than 146 ♦ Alternator faulty, battery se- - Test voltage, charge battery verely discharged ♦ Severe load on the electrical - Increase engine speed system shortly after starting slightly for a few minutes and...
  • Page 58 OCTAVIA Self-Diagnosis less than 78 ♦ Mixture too rich, lambda con- - Operate accelerator at inter- trol produces leaner mixture vals of 20 seconds until learn- ing is completed ♦ Large amount of fuel from ACF system (not in the case of basic setting) ♦...
  • Page 59 OCTAVIA Self-Diagnosis Display group 001 Basic function: Read measured value block 1 K Readout in display → 1.0...2.5 0...5 ° XX.X° BTDC K Display blocks ä 07.97 : 3...12° BTDC Ignition angle 08.97 ä : 6...12° BTDC Throttle valve angle Readout when accelerator fully depressed is 80...90...
  • Page 60 OCTAVIA Self-Diagnosis Test table display group 001 Display block Readout on V.A.G 1552 Cause of fault Rectifying fault less than 1.0 ♦ Smaller readouts can only oc- cur when driving on overrun greater than 2.5 ♦ Poor idling (not running on all...
  • Page 61 OCTAVIA Self-Diagnosis Read measured value block 2 K Readout in display → 1.0...2.5 2.0 ..5.0 2.0...4.0 K Display blocks Inducted air mass Corrected injection time per power stroke Engine load (theoretical injection time per crankshaft revolution) ä 07.97 : 760...840 rpm Idling speed 08.97 ä...
  • Page 62 OCTAVIA Self-Diagnosis Display Cause of fault less than 2.0 ♦ Large quantity of unmetered - Eliminate unmetered air air between intake manifold and air mass meter greater than 4.0 ♦ Gear engaged (automatic - Move selector lever into P or gearbox) ♦...
  • Page 63 OCTAVIA Self-Diagnosis ♦ see also display group 001, display block 1 ⇒ page 01-43 less than 10 V ♦ Alternator faulty, battery se- - Test voltage, charge battery verely discharged ♦ Electrical system subject to - Increase engine speed slightly...
  • Page 64 OCTAVIA Self-Diagnosis idle Read measured value block K Readout in display → speed blocks state part air mass automatic readout is always displayed in case models manual air mass learned on models automatic valve ♦ see display display block ⇒...
  • Page 65 OCTAVIA Self-Diagnosis Display group idling Read measured value block K Readout in display → blocks mass controller speed is displayed in steps speed ä ä Notes on display block 3: As a result of a change in the load conditions at idling The difference as a result of „drift“...
  • Page 66 OCTAVIA Self-Diagnosis idling Read measured value block K Readout in display → blocks Ignition angle ä ä controller Idling controller Idling speed ä ä tolerance range see display group display block page see display group display block page engine too...
  • Page 67 OCTAVIA Self-Diagnosis Display group Read measured value block K Readout in display → blocks correction tank system active ratio solenoid valve activated ratio 0 means closed ratio means open probe controller display group Display on . 1552 of fault readout does not vary...
  • Page 68 OCTAVIA Self-Diagnosis Notes on display Notes on display ♦ The voltage signal „rich mixture (low level of residual ♦ In the case of a readout of 0.3, the engine is supplied oxygen)“ is at approx. 0.7...1.0 V (related to reference with a very rich mixture from the ACF system.
  • Page 69 OCTAVIA Self-Diagnosis Display groups 008 to 099 Display group learned Read measured value block K Readout in display → active n. active adaptation blocks means solenoid valve activated ter is pulsed means solenoid valve activated is constantly closed means correction...
  • Page 70 OCTAVIA Self-Diagnosis Notes on display ♦ Low values indicate that the engine is running too rich ♦ mul = multiplicative - The fault (e.g. faulty injector) has and for this reason the lambda control produces a leaner an increasingly pronounced effect as engine speed mixture.
  • Page 71 OCTAVIA Self-Diagnosis Display group learned Read measured value block K Readout in display → blocks learned value at speed probe controller speed ä ä Display group fuel tank Read measured value block K Readout in display → blocks Activated readout...
  • Page 72 OCTAVIA Self-Diagnosis Notes on display group ♦ The ♦ T ⇒ ♦ ♦ The ♦ Notes on display block ♦ ♦ Notes on display block ♦ ♦ ⇒ ♦ ------------ ------------ Edition 03.98 S00.5107.52.20...
  • Page 73 OCTAVIA Self-Diagnosis Display group 01 fuel Read measured value block 11 K Readout in display → 1.0...2.5 0.5...1.5 blocks readout applies only to any load as a sult ancillaries alternator Road speed load speed ä ä Notes on display block...
  • Page 74 OCTAVIA Self-Diagnosis Read measured value block → blocks Notes on display group Read measured value block → blocks load Notes on display group ------------ ------------ Edition 03.98 S00.5107.52.20...
  • Page 75 OCTAVIA Self-Diagnosis Display group Read measured value block → blocks load Notes on display group 015: With this display group it is possible to check the igni- Causes for retardation of ignition angle: display group tion angle retardation of cylinders 3 and 4 at certain page 01-58.
  • Page 76 OCTAVIA Self-Diagnosis Read measured value block → blocks load Notes on display group 017: In order to warm up the catalytic converter as rapidly - Engine speed more than 4000 rpm as possible to its operating temperature after a cold - Engine load greater than 7.0 ms...
  • Page 77 OCTAVIA Self-Diagnosis ä 07.97 Display group 019, torque reduction: (automatic gearbox) Read measured value block 19 K Readout in display → 0...6800 ° CRA K Display blocks Ignition angle Operating state: X = no gearbox control signal X = gearbox control signal...
  • Page 78 OCTAVIA Self-Diagnosis Display group 020, operating states: Read measured value block K Readout in display → blocks compressor displayed models capacity capacity displayed on models Selector lever position, displayed on models manual ä speed ä : Display group 021, lambda control operating state:...
  • Page 79 OCTAVIA Self-Diagnosis ä Read measured value block K Readout in display → blocks stop valve positioner stop o valve positioner stop valve positioner demand display Note on display block 1: Note on display blocks 1, 2, 3 and 4: If the specified readout is not achieved, adapt engine con- If the specified readout is again not achieved after carry- trol unit to the throttle valve control unit -J338 ⇒...
  • Page 80 OCTAVIA Self-Diagnosis 08.97 ä Display group 023, adaptation of t Read measured value block K Readout in display → blocks stop valve positioner stop valve positioner stop valve positioner demand display Note on display block 1: Note on display blocks 1, 2, 3 and 4:...
  • Page 81 OCTAVIA Self-Diagnosis Display group Read measured value block K Readout in display → 0...6800 blocks otal ignition angle retardation cylinders angle load speed Notes on display group 024: As soon as any signs of knocking are detected, the An ignition angle retardation of e.g. 3° CRA at all cylin-...
  • Page 82 OCTAVIA Self-Diagnosis Note on display block 4: There are only two positions for the variable camshaft, the normal position and the switched position. In order to acti- vate the switched position of the camshaft, the car should be accelerated in second gear when driving slowly (about 1000 rpm) with the accelerator pedal depressed.
  • Page 83 OCTAVIA Self-Diagnosis ä Read measured value block K Readout in display → blocks in normal position position load see display display block ⇒ speed Note on display block There are only two positions for the variable camshaft, the normal position and the switched position. In order to acti-...
  • Page 84 OCTAVIA Self-Diagnosis 08.97 ä Read measured value block K Readout in display → blocks in normal position position ariable intake load see display display block ⇒ speed Meaning Readout condition not actuation not active Readout condition actuation active intake Note on display block...
  • Page 85 OCTAVIA Self-Diagnosis Display group 098, adaptation of When display group 098 is selected in function 04 „Basic set- ting“, the throttle valve control unit -J338 is adapted to the engine control unit. Basic setting 98 Readout in display → 0...5 0...5...
  • Page 87 OCTAVIA Fuel Formation / Fuel Injection Servicing fuel injection system - valid ä 07.97 Summary of fitting locations 1 - Solenoid valve 1 for activated charcoal ♦ On right on underside of vehicle be- filter -N80 low a cover ♦ Activated charcoal filter system ⇒...
  • Page 88 OCTAVIA Fuel Preparation / Fuel Injection 7 - Air mass meter (G70) 14 - 3-pin connector ♦ For engine speed sender 8 - Coolant temperature sender (G62) 15 - Knock sensor 1 (G61) 9 - Fuel pressure regulator 16 - 3-pin connector 10 - Injector (N30...N33)
  • Page 89 OCTAVIA Fuel Formation / Fuel Injection Servicing fuel injection system - valid 08.97 ä Summary of fitting locations 1 - Solenoid valve 1 for activated charcoal ♦ On right on underside of vehicle be- filter -N80 low a cover ♦ Activated charcoal filter system ⇒...
  • Page 90 OCTAVIA Fuel Formation / Fuel Injection 7 - Air mass meter (G70) and intake air 13 - Knock sensor 2 (G66) temperature sender (G42) 14 - 3-pin connector 8 - Coolant temperature sender (G62) ♦ For engine speed sender 9 - Fuel pressure regulator 15 - Knock sensor 1 (G61) 10 - Injector (N30...N33)

  • Page 91: Rules For Cleanliness

    OCTAVIA Fuel Preparation / Fuel Injection Servicing fuel injection system Servicing ignition system ⇒ Repair Group 28 Notes: ♦ The control unit for the fuel injection and ig- nition system is equipped with a fault memory. The fault memory should be inter-...
  • Page 92 OCTAVIA Fuel Formation / Fuel Injection alid ä ♦ Replace if damaged ♦ 3-pin ♦ For air mass meter (G70) ♦ black, 2-pin ♦ for intake air temperature sender 0 Air meter (G42) ------------ 24-4 ------------ Edition 03.98 S00.5107.52.20...
  • Page 93 OCTAVIA Fuel Formation/Fuel Injection 11 - Air filter 26 - Retaining clamp ♦ Disassembling and assembling ⇒ page 24-9 27 - Coolant temperature sender (G62)* ♦ With coolant temperature gauge 12 - Inlet connection sender (G2) ♦ Marking: yellow ring 13 - Support ♦...
  • Page 94 OCTAVIA Fuel Formation / Fuel Injection alid ä ♦ ♦ For (G70) meter ♦ For ------------ ------------ Edition 03.98 S00.5107.52.20...
  • Page 95 OCTAVIA Fuel Formation/Fuel Injection 11 - Air filter ♦ Disassembling and assembling ♦ Disassembling and assembling ⇒ page ⇒ page 12 - Inlet connection ♦ 13 - Fuel ♦ 14 - control unit ♦ 1 - on-return ⇒ page ♦...
  • Page 96 OCTAVIA Fuel Formation / Fuel Injection ä ♦ Vacuum ♦ ♦ black, 2-pin Vacuum connection ♦ for intake air temperature sender ♦ (G42) esting ⇒ page ♦ ------------ ------------ Edition 03.98 S00.5107.52.20...
  • Page 97 OCTAVIA Fuel Formation/Fuel Injection ♦ For throttle cable ♦ To heat exchanger ♦ Adjusting throttle cable: ⇒ 1.8-ltr./92 kW Engine Mechanical Compo- nents; Repair Group 20; Adjusting throttle ♦ To branch connector cable onnector ♦ black, 8-pin ♦ Replace ♦ For throttle valve control unit (J338) ♦...
  • Page 98 OCTAVIA Fuel Formation / Fuel Injection ä acuum ♦ Removing and installing ♦ To non-return valve for vacuum res- ⇒ Engine Mechanical Components; Repair ervoir (item 17) Group 15; Removing and installing cylinder head cover acuum ♦ To intake hose acuum ♦...
  • Page 99 OCTAVIA Fuel Formation/Fuel Injection ♦ For throttle cable ♦ For vacuum reservoir integrated in ♦ Adjusting throttle cable: intake manifold ⇒ 1.8-ltr./92 kW Engine Mechanical Compo- ♦ Ensure correctly installed; if incorrectly nents; Repair Group 20; Adjusting throttle valve does not operate; ac-...
  • Page 100 OCTAVIA Fuel Formation / Fuel Injection ä acuum ♦ Clipped onto fuel rail ♦ To top part of intake manifold Fuel ♦ For knock sensor 1 (G61), black con- ♦ Testing pressure regulator and hold- nector ing pressure ⇒ page 24-27 ♦...
  • Page 101 OCTAVIA Fuel Formation / Fuel Injection 4 Feed line ♦ Secure hose at fuel rail with spring strap clip ♦ Replace ♦ Hose with white marking 0 Intermediate ♦ Inspect for cracks ♦ Secure hose at fuel rail with spring strap clip ♦...
  • Page 102 OCTAVIA Fuel Formation / Fuel Injection ä Injector ♦ Secure hose at fuel rail with spring ♦ Testing ⇒ page 24-35.2 strap clip acuum ♦ Hose with blue marking ♦ From top part of intake manifold to fuel pressure regulator Fuel ♦...
  • Page 103 OCTAVIA Fuel Formation / Fuel Injection ♦ Attached with fuel rail to bottom part ♦ For injectors (N30...N33) of intake manifold onnector element ♦ For Hall sender (G40) 8 Fuel rail ♦ Replace if damaged 9 Feed line ♦ Secure hose at fuel rail with spring strap clip ♦...
  • Page 104 OCTAVIA Fuel Preparation / Fuel Injection Important! The fuel system is pressurised! Place cleaning rags around the connection point before opening the system. Then, release the pressure by carefully detaching the connection point. Pay attention to the following points in order to...
  • Page 105 OCTAVIA Fuel Formation/Fuel Injection ♦ 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 possi- ble.
  • Page 106 OCTAVIA Fuel Preparation / Fuel Injection tion Notes: ♦ Idling speed, ignition timing and CO content cannot be adjusted. ♦ Idling speed is tested during the basic set- ting of the engine. ♦ The CO content is maintained at the speci- fied value by the lambda control.
  • Page 107 OCTAVIA Fuel Formation/Fuel Injection ♦ Continue running engine at idling speed. Test of vehicle systems HELP K Readout in display: Enter address word XX Read measured value block (function 08) and select display group 005 ⇒ page 01-49. Read measured value block 5 K Readout in display: →...
  • Page 108 OCTAVIA Fuel Formation/Fuel Injection ♦ Diode test lamp (e.g. V.A.G 1527 B) ♦ Adapter cable set (e.g. V.A.G 1594 A) ♦ Test box V.A.G 1598/22 Testing for leaks The solenoid valve is closed in the de-energized state. Detach the hose from the activated charcoal filter solenoid valve (N80).
  • Page 109 OCTAVIA Fuel Formation/Fuel Injection Unplug the connector at the ACF valve. Connect diode test lamp between contact 1 of the connector and engine earth. Operate the starter. Specification: The diode test lamp must come If the diode test lamp does not come on, test the cable connection from contact 1 to fuse 43 for continuity, and repair if necessary.
  • Page 110 OCTAVIA Fuel Formation/Fuel Injection Testing control unit Testing K The Note: ♦ ⇒ ♦ ⇒ Testing idling testers and aids ♦ ♦ T ♦ ♦ ♦ ⇒ ⇒ ------------ ------------ Edition 10.99 S00.5107.53.20...
  • Page 111 OCTAVIA Fuel Preparation / Fuel Injection The ignition should be switched on when carry- ing out this step. Read measured value block 98 K Readout in display: X.XXX V X.XXX V Idling ....Display field 3 should indicate „Idling“. Open throttle valve slowly.
  • Page 112 OCTAVIA Fuel Preparation / Fuel Injection ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 V.A.G ♦ V.A.G ♦ cable set V.A.G ♦ ♦ Procedure hose the throttle ⇒ at the throttle Important! V.A.G at the the e ⇒...
  • Page 113 OCTAVIA Fuel Preparation / Fuel Injection If the specifications are not achieved, switch off the ignition. Connect test box V.A.G 1598/22 to the wir- ing loom to the engine control unit ⇒ page 24-48, Replacing engine control unit. Unplug the 8-pin connector at the throttle valve control unit.
  • Page 114 OCTAVIA Fuel Formation / Fuel Injection Carry out basic setting of the throttle valve control unit ⇒ page 24-53. If it is not possible to start or successfully complete the basic setting, replace engine control unit ⇒ page 24-48. ä...
  • Page 115 OCTAVIA Fuel Formation / Fuel Injection Ω connector unit connector or ⇒ Edition 03.98 ------------ 24-21 ------------ S00.5107.52.20...
  • Page 116 OCTAVIA Fuel Formation/Fuel Injection Testing sender ä testers and aids ♦ V ♦ ♦ ♦ ♦ ♦ Notes: ♦ If a fault exists at the sender or at the cable connections, the control unit operates with a substitute temperature of 19.5 °C.
  • Page 117 OCTAVIA Fuel Formation / Fuel Injection approx. -46 °C Open circuit or short ⇒ page circuit to positive 24-21.2 approx. 141 °C Short circuit to earth ⇒ page 24-21.3 approx. ⇒ page ambient 24-21.4 temperature If the temperature displayed is below the...
  • Page 118 OCTAVIA Fuel Formation / Fuel Injection connector unit connector ⇒ ------------ 24-21.3 ------------ Edition 03.98 S00.5107.52.20...
  • Page 119 OCTAVIA Fuel Formation / Fuel Injection ∞ Ω ⇒ readout → ♦ ♦ ♦ ♦ ♦ Edition 03.98 ------------ 24-21.4 ------------ S00.5107.52.20...
  • Page 120 OCTAVIA Fuel Preparation / Fuel Injection Notes: ♦ The ♦ ⇒ Important! Switch on the relevant measuring range before connecting the test cables and pay attention to the test conditions in order to avoid damaging the elec- tronic components. ⇒...
  • Page 121 OCTAVIA Fuel Formation/Fuel Injection Ω Ω Ω ⇒ coolant ♦ ♦ ♦ Notes: ♦ For the operational test of the coolant tem- perature sender, refer also to Reading meas- ured value block, display group 003, display block 3 ⇒ page 01-46.
  • Page 122 OCTAVIA Fuel Formation/Fuel Injection Unplug the connector at the coolant ture contact contact of the range for the range range the re- for the range ♦ ♦ replace to the control to the to the control page ------------ ------------ Edition 10.99...
  • Page 123 OCTAVIA Fuel Formation/Fuel Injection Ω Ω ⇒ control unit ♦ ♦ ♦ ♦ ♦ Edition 10.99 ------------ ------------ S00.5107.53.20...
  • Page 124 OCTAVIA Fuel Formation/Fuel Injection ⇒ ------------ ------------ Edition 10.99 S00.5107.53.20...
  • Page 125 OCTAVIA Fuel Preparation / Fuel Injection fuel regulator and required ♦ Pressure measuring device e.g. V.A.G 1318 ♦ Pressure hose with connections e.g. V.A.G 1318/8 ♦ Adapter e.g. V.A.G 1318/9 ♦ Adapter e.g. V.A.G 1318/7 l Delivery and fuel pump o.k.; testing: ⇒...
  • Page 126 OCTAVIA Fuel Preparation / Fuel Injection ------------ ------------ Edition 11.96 S00.5107.51.20...
  • Page 127 OCTAVIA Fuel Preparation / Fuel Injection If the pressure again drops: Open the shut-off cock of the pressure meas- uring device V.A.G 1318 (lever in direction of flow). Start the engine and run at idling speed. After the pressure has built up, switch off the ignition.
  • Page 128 OCTAVIA Fuel Formation / Fuel Injection ä Warning! Fuel feed line is pressurized! Place cleaning rags around the connection point before detaching the hose connections. Then, release pressure by care- fully detaching the hose. ------------ ------------ Edition 03.98 S00.5107.52.20...
  • Page 129 OCTAVIA Fuel Preparation / Fuel Injection ♦ ♦ ♦ Note: Edition 11.96 ------------ 24-31 ------------ S00.5107.51.20...
  • Page 130 OCTAVIA Fuel Formation / Fuel Injection Test procedure - valid 08.97 ä Remove intake manifold trim panel -arrows-. Unclip throttle cable from the cable guide. Detach vacuum hose from the fuel pressure regulator. Remove top part of intake manifold. Detach fuel feed pipe -1- and fuel return-flow line -2- (press release catches).
  • Page 131 OCTAVIA Fuel Formation / Fuel Injection Valid for all models ♦ ♦ ♦ Edition 03.98 ------------ 24-31.2 ------------ S00.5107.52.20...
  • Page 132 OCTAVIA Fuel Preparation / Fuel Injection ⇒ ------------ 24-32 ------------ Edition 11.96 S00.5107.51.20...
  • Page 133 OCTAVIA Fuel Preparation / Fuel Injection Note: ⇒ Note: Edition 11.96 ------------ 24-33 ------------ S00.5107.51.20...
  • Page 134 OCTAVIA Fuel Formation / Fuel Injection ä ä ä Special required ♦ ♦ ♦ ♦ ♦ ------------ 24-34 ------------ Edition 03.98 S00.5107.52.20...
  • Page 135 OCTAVIA Fuel Formation / Fuel Injection l Engine speed sender o.k. l Fuel pump relay o.k. Remove the ignition cable guide. Electrical Unplug the connector at the injector to be tested. Use V.A.G 1526 A to carry out a resistance measurement between the contacts of the injector.
  • Page 136 OCTAVIA Fuel Formation / Fuel Injection Note: Diode test lamps with a low current consump- tion do not go out completely between the flash pulses, but continue to glow slightly and become significantly brighter during the flash pulse. Warning! Set the relevant measuring range before connect-...
  • Page 137 OCTAVIA Fuel Formation / Fuel Injection ä required ♦ Test box V.A.G 1598/22 ♦ Hand-held multimeter, e.g. V.A.G 1526 A or multimeter V.A.G 1715 ♦ Diode test lamp, e.g. V.A.G 1527 ♦ Adapter cable set V.A.G 1594 A ♦ Current flow diagram l Engine speed sender o.k.
  • Page 138 OCTAVIA Fuel Formation / Fuel Injection condition l Fuse 32 for injectors o.k. Unplug connector at the injector to be tested. Connect diode test lamp V.A.G 1527 be- tween contact 1 and engine earth. Operate starter for a few seconds; the diode test lamp should come on.
  • Page 139 OCTAVIA Fuel Formation / Fuel Injection If the diode test lamp does not flash: Connect test box V.A.G 1598/22 to the en- gine control unit wiring loom. Warning! Set the relevant measuring range before connect- ing the test cables and pay attention to the test conditions in order to avoid damaging the elec- tronic components.
  • Page 140 OCTAVIA Fuel Formation/Fuel Injection Testing fuel tion ♦ T ♦ ♦ ♦ ♦ Test condition Note: K The fuel pump relay is located in the electrical centre in the interior of the vehicle behind the storage compartment in the driver footwell, re- lay position 4.
  • Page 141 OCTAVIA Fuel Preparation / Fuel Injection If the If the ⇒ If the ⇒ If the and actuation Important! If the ⇒ actuation Edition 11.96 ------------ ------------ S00.5107.51.20...
  • Page 142 OCTAVIA Fuel Formation / Fuel Injection Note: Diode test lamps with a low current consump- tion do not go out completely continue to glow until the starter is If the diode test lamp does not test test to the of the...
  • Page 143 OCTAVIA Fuel Formation / Fuel Injection l Fuse ⇒ ⇒ ⇒ Edition 03.98 ------------ ------------ S00.5107.52.20...
  • Page 144 OCTAVIA Fuel Formation / Fuel Injection air mass meter Warning! ⇒ ⇒ ⇒ air mass meter ------------ ------------ Edition 03.98 S00.5107.52.20...
  • Page 145 OCTAVIA Fuel Formation / Fuel Injection for air mass meter or -J220 esting air mass meter - valid ä Special tools, testers and aids required ♦ ♦ ♦ ♦ ♦ est conditions Edition 03.98 ------------ ------------ S00.5107.52.20...
  • Page 146 OCTAVIA Fuel Formation / Fuel Injection Testing operation Connect the vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 ⇒ page 01-3, engine idling. Select Reading measured value block (func- tion 08) and display group 002 ⇒ page 01-45. Read measured value block 2 K Readout in display: →...
  • Page 147 OCTAVIA Fuel Formation / Fuel Injection Testing voltage supply of air mass meter (G70) Warning! Switch on the relevant measuring range before connecting the test cables and pay attention to the test conditions in order to avoid damaging the elec- tronic components.
  • Page 148 OCTAVIA Fuel Formation / Fuel Injection Connector Test box for air mass V.A.G 1598/22 meter G70 or -J220 Testing intake system for leaks (unmetered air) Special tools, testers and aids required ♦ ♦ Test procedure Notes: ♦ The vacuum in the intake system draws in the leak detection spray with the unmetered air.

  • Page 149: Testing Lambda Control

    OCTAVIA Fuel Formation / Fuel Injection Read measured value block 9 K Readout in display: → (1...4 = display blocks) Note the engine speed shown in display block Note the lambda probe voltage shown in dis- play block 3 and the range within which it varies.
  • Page 150 OCTAVIA Fuel Formation / Fuel Injection In view of the steep voltage jump, the lambda control is not able to maintain constant the ideal mixture composition which corresponds to λ = 1.0. A so-called reference voltage of approx. 0.4...0.5 V is programmed in the engine control unit for analysing the signal from the lambda probe.
  • Page 151 OCTAVIA Fuel Formation / Fuel Injection cold condition l No fault in respect of lambda control stored; rectify any faults and erase fault memory. The time which elapses until the lambda con- trol is activated (probe temperature required about 300 °C) is determined primarily by the following factors: ♦...
  • Page 152 OCTAVIA Fuel Formation / Fuel Injection ------------ ------------ Edition 03.98 S00.5107.52.20...
  • Page 153 OCTAVIA Fuel Preparation / Fuel Injection Read measured value block 7 K Readout in display: → The signal voltage of the lambda probe appears in display field 2. If the vehicle is cold or lambda control not oper- ating: 0.45...0.50 V.
  • Page 154 OCTAVIA Fuel Preparation / Fuel Injection operation ⇒ ⇒ ⇒ ------------ 24-44 ------------ Edition 11.96 S00.5107.51.20...
  • Page 155 OCTAVIA Fuel Formation / Fuel Injection The mixture adaptation is adaptive, in other words differences between engines (nozzle flow, compression, fuel pressure, etc.) are detected by means of the lambda control and compen- sated for by adapting the basic injection times programmed in the map.
  • Page 156 OCTAVIA Fuel Formation / Fuel Injection Unplug the connector t the on the right to the Warning! Switch on the relevant measuring range before connecting the test cables and pay attention to the test conditions in order to avoid damaging the elec- tronic components.
  • Page 157 OCTAVIA Fuel Formation/Fuel Injection ⇒ ⇒ ⇒ Edition 10.99 ------------ ------------ S00.5107.53.20...
  • Page 158 OCTAVIA Fuel Formation / Fuel Injection ------------ ------------ Edition 03.98 S00.5107.52.20...
  • Page 159 OCTAVIA Fuel Formation/Fuel Injection and actuation Note: ⇒ ⇒ ⇒ Edition 10.99 ------------ ------------ S00.5107.53.20...
  • Page 160 OCTAVIA Fuel Formation/Fuel Injection Notes: ♦ T ♦ coding and ing engine control unit engine control unit Note: Notes: ♦ ♦ Notes: ♦ ♦ ------------ ------------ Edition 10.99 S00.5107.53.20...
  • Page 161 OCTAVIA Fuel Formation/Fuel Injection Perform coding of the new engine control unit ⇒ page 24-49. Adapt engine control unit to the throttle valve control unit (J338) ⇒ page 24-51. Adapt engine control unit to the electronic immobiliser ⇒ page 24-50.
  • Page 162 OCTAVIA Fuel Preparation / Fuel Injection electronic est condition l Authorised car key available Procedure Connect vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 ⇒ page 01-3. Switch on the ignition. Press key 1 for „Rapid data transfer“. Press the keys 1 and 7 for the address word „Dash panel insert“...
  • Page 163 OCTAVIA Fuel Preparation / Fuel Injection When the basic setting is carried out, the en- gine control unit learns the stop positions of the throttle valve control unit with the ignition swit- ched on and the engine not running. Note:...
  • Page 164 OCTAVIA Fuel Preparation / Fuel Injection K If → → e → → ⇒ → ⇒ → ⇒ → → → ⇒ → → Note: ♦ ♦ ------------ ------------ Edition 11.96 S00.5107.51.20...
  • Page 165 OCTAVIA Fuel Preparation / Fuel Injection ♦ The throttle valve control unit or the cable connection is faulty. After basic setting is aborted the fault „Basic setting not carried out, fault in the basic setting“ is entered in the fault memory. When the igni- tion is next switched on, basic setting is once again carried out automatically.
  • Page 166 OCTAVIA Fuel Preparation / Fuel Injection ⇒ Note: Display group number 001 is an example in or- der to present the sequence. → Notes: ♦ In the case of display group number 000 the readouts appear as decimals. ♦ Each time the PRINT key (of V.A.G 1551) is pressed, the current readout in the display is printed out.

  • Page 167: Testing Additional Signals

    OCTAVIA Fuel Formation / Fuel Injection Testing additional signals Testing Notes: ♦ The ♦ The ♦ The testers and aids ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 ♦ Test box V.A.G 1598/22 ♦ Hand-held multimeter, e.g. V.A.G 1526 A or multimeter V.A.G 1715...
  • Page 168 OCTAVIA Fuel Formation / Fuel Injection Read value K Readout in display: → in display in display in display suddenly and lease it pedal is idly in display does not test Test t unit to unit and to positive and open ⇒...
  • Page 169 OCTAVIA Fuel Formation/Fuel Injection ♦ T ♦ ♦ ♦ ♦ ⇒ → Edition 10.99 ------------ ------------ S00.5107.53.20...
  • Page 170 OCTAVIA Fuel Formation/Fuel Injection loom cable ⇒ cable ⇒ Testing selector automatic Note: Earth is connected to contact 22 at the engine control unit by the starter lockout and reversing light relay -J226 when the selector lever is moved into position P or N.
  • Page 171 OCTAVIA Fuel Formation/Fuel Injection Depress the footbrake and move selector lever into a gear. Specification: ”Gear ENG” If the readout does not appear as described, connect test box V.A.G 1598/22 to the wir- ing loom to the engine control unit ⇒...
  • Page 172 OCTAVIA Fuel Formation/Fuel Injection ⇒ ⇒ Testing throttle valve position Notes: ♦ This signal is used by the automatic gear- box control unit in conjunction with the en- gine speed signal for various purposes, in- cluding calculating the engine torque which is output.
  • Page 173 OCTAVIA Fuel Formation/Fuel Injection ⇒ ⇒ ⇒ Notes: ♦ The ♦ The tools, testers and aids required ♦ ♦ ♦ ♦ ♦ ♦ ⇒ → Edition 10.99 ------------ ------------ S00.5107.53.20...
  • Page 174 OCTAVIA Fuel Preparation / Fuel Injection ⇒ Note: ⇒ control Notes: ♦ ♦ The ♦ ♦ ♦ ♦ ♦ ------------ ------------ Edition 11.96 S00.5107.51.20...
  • Page 175 OCTAVIA Fuel Preparation / Fuel Injection ♦ Adapter cable set V.A.G 1594 A ♦ Current flow diagram Connect V.A.G 1552 ⇒ page 01-3. Carry out a road test and select Reading measured value block (function 08) and dis- play group 019 ⇒ page 01-57.
  • Page 176 OCTAVIA Fuel Formation / Fuel Injection ä condition ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ------------ ------------ Edition 03.98 S00.5107.52.20...
  • Page 177 OCTAVIA Fuel Formation / Fuel Injection Testing vacuum testers and aids ♦ Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 ♦ Manually-operated vacuum pump V.A.G 1390 ♦ Adapter cable set V.A.G 1594 A Run the engine at idling speed for 2 to 3 min- utes (to build up vacuum).
  • Page 178 OCTAVIA Fuel Formation/Fuel Injection ⇒ tools, testers and aids required ♦ ♦ ♦ ♦ Test condition ------------ ------------ Edition 10.99 S00.5107.53.20...
  • Page 179 OCTAVIA Fuel Formation / Fuel Injection Electrical Unplug Ω Unplug ⇒ Ω ⇒ Edition 03.98 ------------ ------------ S00.5107.52.20...
  • Page 180 OCTAVIA Fuel Formation / Fuel Injection actuation ⇒ ⇒ ------------ ------------ Edition 03.98 S00.5107.52.20...
  • Page 181 OCTAVIA Fuel Formation/Fuel Injection Testing signal steering (Models from Model Year 1998) testers and aids ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Test rocedure Connect vehicle system tester V.A.G 1552 and select the engine electronics control unit with the ”address word”...
  • Page 182 OCTAVIA Fuel Formation/Fuel Injection If the specification is not achieved: Connect test box V.A.G 1598/22 to the wir- ing loom to the control unit. Unplug the 2-pin connector -1- from the power steering pressure switch (F88) -2-. Test the cables between test box and 2-pin connector for continuity according to current flow diagram.

  • Page 183: Ignition System Page

    OCTAVIA Ignition System Servicing ignition system List of components 5 - Cover 6 - Spark plug, 30 Nm ♦ Use special spark plug wrench for re- moving and installing ♦ Type and electrode gap ⇒ page 28-3, Technical data of ignition system 7 - Connector ♦...

  • Page 184: Safety Precautions

    OCTAVIA Ignition System 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.

  • Page 185: Testing Components And Functions

    OCTAVIA Ignition System Technical data of ignition system Engine code letters Engine speed sender Resistance approx. 450...1000 Ω Ignition system Twin-spark ignition system with two ignition coils Spark plugs Tightening torque 30 Nm Part No. 101 000 033 AA Manufacturer’s designation...
  • Page 186 OCTAVIA Ignition System l Battery voltage at least 11.5 V l Engine speed sender o.k.; Testing ⇒ page 24-21 l Hall sender o.k.; Testing ⇒ page 28-8 Note: Ignition coils and power output stage are a sin- gle component and cannot be replaced sepa- rately.
  • Page 187 OCTAVIA Ignition System Connect diode test lamp V.A.G 1527 be- tween engine earth and contact 2 of connec- tor (positive supply). Specification: Diode test lamp should come on. If the specifications are not achieved, test for open circuit in wiring according to current flow diagram and rectify any open circuit or test the fuse.
  • Page 188 OCTAVIA Ignition System esting sensors testers required ♦ Test box V.A.G 1598/22 ♦ Hand-held multimeter V.A.G 1526 or multi- meter V.A.G 1715 ♦ Adapter cable set V.A.G 1594 ♦ Current flow diagram Notes: ♦ Reading measured value block, display groups 012, 013, 014 and 015 for testing operation of the knock sensors.
  • Page 189 OCTAVIA Ignition System ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder Contact assignment of plug connection: Test signal wire of knock sensor 1 -G61 from contact 1 of connector in engine compart- ment to socket 68 of test box for continuity.
  • Page 190 OCTAVIA Ignition System K l Knock sensor 1 1 (Signal) 2 (Earth) 3 (Screening) l Knock sensor 2 1 (Signal) 2 (Earth) 3 (Screening) esting ♦ Test box V.A.G 1598/22 ♦ Diode test lamp, e.g. V.A.G 1527 ♦ Hand-held multimeter, e.g. V.A.G 1526 or multimeter V.A.G 1715...
  • Page 191 OCTAVIA Ignition System ♦ The offset by one revolution does not have any perceptible effects on fuel in- jection. Fuel injection then does not take place with the inlet valve opened but „ad- vanced“ (upstream of the closed inlet valve). Consequently the quality of the mixture formation is only slightly affected.
  • Page 192 OCTAVIA Ignition System Test the cable connection from the Hall sender ..to the engine control unit for open circuit in wiring and also for short circuit to positive and to earth. Contact at 3-pin Contact connector at connector...
  • Page 193 OCTAVIA Ignition System esting ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 l Operating temperature of at least 80 °C. K Installation position of solenoid valve. esting The inlet camshaft is adjusted in line with en- gine load and speed. The electric camshaft ad- juster valve directs oil pressure to the camshaft adjuster (mechanical adjusting device).
  • Page 194 OCTAVIA Ignition System Actuation of the camshaft adjustment is active. Notes: ♦ Display field 4 indicates whether an adjust- ment of the camshaft has in fact taken place. ♦ The camshaft adjustment takes place only at full throttle; for this reason check the readout in display field 1.
  • Page 195 OCTAVIA Ignition System If the valve does not click, switch off the igni- tion. Unplug the connector from the solenoid valve -N205. Use V.A.G 1526 A to carry out a resistance measurement between the contacts of the valve. Specification: 10 ... 18 Ω...

  • Page 196: Ignition System

    OCTAVIA Ignition System ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ------------ 28-14 ------------ Edition 11.96 S00.5107.51.20...

Table of Contents