Skoda Octavia1999 Service Manual

1.4-ltr./44 kw engine, simos 3pb fuel injection and ignition system

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Workshop Manual

OCTAVIA

1.4-ltr./44 kW Engine, Simos 3PB Fuel

Injection and Ignition System

Service Department. Technical Information

S00.5126.50.20 Edition 07.99

Table of Contents

Summary of Contents for Skoda Octavia1999

Page 1 Service Workshop Manual OCTAVIA 1.4-ltr./44 kW Engine, Simos 3PB Fuel Injection and Ignition System Service Department. Technical Information S00.5126.50.20 Edition 07.99...
Page 2 The Service Manual is intended only for use within the Škoda Organisation; it is not permitted to pass it onto third persons. Printed in CR © 1999 ŠKODA AUTO a. s.
Page 3 Service List of Supplements for Workshop Manual Edition: 06.00 OCTAVIA 1.4-ltr./44 kW Engine, Simos 3PB Fuel Injection and Ignition System Replaces List of Supplements - Edition: 07.99 Subject Edition Article Number Supple- ment 07.99 Basic Edition Workshop Manual S00.5126.50.20 06.00 Supplement to Basic Edition S00.5126.51.20 Contents ⇒...
Page 5: Table Of Contents
OCTAVIA Service Contens Self-diagnosis Page Self-diagnosis ..........................01-1 Features of self-diagnosis ......................01-1 Technical data of self-diagnosis ....................01-1 Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit .. 01-2 Interrogating and erasing fault memory ..................01-4 Fault table ..........................
Page 6: Ignition System
Service OCTAVIA Testing additional signals ......................24-65 Testing engine speed signal ..................... 24-65 Testing fuel consumption signal for multifunction display ............24-65 Testing road speed signal ......................24-65 Testing brake light switch -F and brake pedal switch -F47 ............24-67 Testing clutch pedal switch -F36- .....................
Page 7 OCTAVIA Service Contents Self-diagnosis Page Self-diagnosis ..........................01-1 Features of self-diagnosis ......................01-1 Technical data of self-diagnosis ....................01-1 Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit .. 01-2 Interrogating and erasing fault memory ..................01-4 Fault table ..........................
Page 8 ¡ ¢ £ ¤ ¥ £ ! " # # $ " % ! " % & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & ' ( ) 0 1 &...
Page 9: Self-Diagnosis
OCTAVIA Self-Diagnosis Self-diagnosis Note: Self-diagnosis monitors only a part of the fuel injection and ignition system. Features of self-diagnosis The Simos 3PB control unit is equipped with a fault memory. The fault memory is designed as a permanent memory. If faults occur at the monitored sensors or com- ponents, these are stored in the fault memory with an indication of the fault type.
Page 10: Connecting Vehicle System Tester V.a.g 1552 And Selecting Engine Electronics Control Unit
OCTAVIA Self-Diagnosis Function Requirement Ignition on Engine idling Interrogating fault memory Final control diagnosis Initiating basic setting Erasing fault memory Ending output Reading measured value block Only if engine does not start (starter must be operated for at least 6 seconds). Must be carried out after completing the following operations: Replacing engine control unit, throttle valve...
Page 11 OCTAVIA Self-Diagnosis Procedure Connect vehicle system tester V.A.G 1552 with cable V.A.G 1551/3. After connecting the vehicle system tester: Either, depending on the function desired, switch on the ignition start the engine ⇒ page 01-1, table of „Avail- able Functions“. Notes: ♦...
Page 12: Interrogating And Erasing Fault Memory
OCTAVIA Self-Diagnosis Interrogating and erasing fault memory Special tools, testers and aids required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Procedure Connect vehicle system tester V.A.G 1552 and select engine electronics (address word 01); engine idling for this step ⇒ page 01-2. Only if engine does not start: Switch on ignition.
Page 13 OCTAVIA Self-Diagnosis Test of vehicle systems K Readout in display: → Fault memory is erased! Press the → key. Press keys 0 and 6 for the function „End out- put“ and confirm the entry with the key Q. Rectify the faults displayed by referring to the fault table ⇒...
Page 14: Fault Table
OCTAVIA Self-Diagnosis Fault table Notes: ♦ The fault table is arranged according to the 5-digit fault ♦ If components are shown as faulty: code shown on the left. Test cables and plug connections to these components, and also earth cables of the system according to the ♦...
Page 15 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Possible cause of fault Possible effects Rectifying fault 16501 Coolant temperature sender -G62 Signal too small ♦ Short circuit to earth ♦ Cold start problems at very - Read measured value ♦ Sender -G62 faulty low temperatures block, display group 004, ♦...
Page 16 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Possible cause of fault Possible effects Rectifying fault 16516 Bank 1, probe 1 Voltage too large ♦ Short circuit of signal ca- ♦ Lambda closed-loop con- - Rectify short circuit or ble to positive trol switches to open-loop open circuit in wiring ⇒...
Page 17 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Possible cause of fault Possible effects Rectifying fault 16554 Bank 1, fuel metering sys- Malfunction ♦ Fuel pressure regulator ♦ Engine does not start - Test fuel pressure regula- faulty ♦ Increased emission levels tor and holding pressure ♦...
Page 18 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Possible cause of fault Possible effects Rectifying fault 16556 Bank 1, fuel metering sys- System too rich ♦ Fuel system faulty ♦ Lambda closed-loop con- - Test fuel pressure regula- trol switches to open-loop tor and holding pressure ⇒ page 24-19.
Page 19 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Possible cause of fault Possible effects Rectifying fault 16719 Engine speed sender -G28 Malfunction ♦ Short circuit of lambda ♦ Engine does not start - Rectify open circuit in wir- probe signal wire to earth ing or short circuit.
Page 20 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Possible cause of fault Possible effects Rectifying fault 16825 Tank vent system Flow faulty ♦ -N80 faulty ♦ Irregular idling - Test activated charcoal fil- ♦ Open circuit in wiring or ♦ Smell of fuel ter solenoid valve ⇒...
Page 21 1 ¦ & 1 ¦ & 0 0 ¥ ¨ 2 ¥ ¨ 0 3 § 0 ' ¨ ¥ ' ¡...
Page 23 0 1 1 ! 2 0 1 1 ! 2 3 3 # 1 4 # ! 3 5 ! " 3 % 2 # % 1 ¤...
Page 27 ) 0 0 1 2 ) 0 0 1 2 5 5 0 6 1 5 1 7 5 3 4 8 9 3 4 0 ¤...
Page 28 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Possible cause of fault Possible effects Rectifying fault 17744 Engine torque monitor Control limit exceeded ♦ Leak in intake system ♦ Engine runs in emergency - Test intake system for ♦ Throttle valve control unit mode leaks ⇒...
Page 34 $ $ % $ & ' ( ( $ % ' ( ( $ % 0 0 ( 1 $ 0 2 $ 3 0 ) ) ( ¥...
Page 38: Final Control Diagnosis
OCTAVIA Self-Diagnosis Final control diagnosis With final control diagnosis the following com- ponents are actuated in the order stated: 1. Fuel pump relay (J17) 2. Solenoid valve 1 for activated charcoal filter (N80) Special tools, testers and aids required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Test condition l Fuses o.k.
Page 39 OCTAVIA Self-Diagnosis If the relay does not click: Test the fuel pump relay ⇒ page 24-27. Press the key. Actuate solenoid valve 1 for activated charcoal filter (N80). Press the key. Final control diagnosis K Readout in display: Solenoid valve 1 for activated charcoal filter -N80 The solenoid valve (in front of coolant reser- voir on right) must click until the next control element is actuated by pressing the...
Page 40: Reading Measured Value Block
OCTAVIA Self-Diagnosis Reading measured value block Test conditions l Coolant temperature at least 80 °C l Electrical components switched off (radiator fan must not cut in during the test) Test sequence: Connect vehicle system tester V.A.G 1552 and select engine electronics (address word 01);...
Page 41: Reading Measured Value Block: Display Groups 000 To 010
OCTAVIA Self-Diagnosis Reading measured value block: display groups 000 to 010 Display group 000 (decimal readouts) • Engine idling (coolant temperature not below 80 °C) • All electrical components switched off 10 K Display blocks Specification Equals Learned value of mixture formation part load 110...145 –7...+7 % Learned value of mixture formation idling...
Page 42 OCTAVIA Self-Diagnosis Display block: 3 Engine speed (idling speed) Readout in V.A.G 1552 Possible cause of fault Rectifying fault less than 23 ♦ Throttle valve control unit -J338 jamming or faulty - Test throttle valve control unit ⇒ page 24-56. greater than 27 ♦...
Page 43 OCTAVIA Self-Diagnosis Display group 001 - base functions: Read measured value block 1 K Readout in display → 730...870 75...105 -10.0...10.0 xxxxxxxx °C Setting condition for basic setting ⇒ Table below Lambda control value Coolant temperature Engine speed (idling speed) Note on display block 4: Meaning of digits in 8-digit numerical block for setting condition for throttle valve adaptation: 1 = condition met...
Page 44 ∠ ⇒ OCTAVIA Self-Diagnosis Display group 003 - base functions: Read measured value block 3 K Readout in display: → 0...12 mbar (g/s) °) BTDC Ignition angle (actual value) Ignore readout ⇒ Ignore readout Idling speed page 01-35, display group number 001 Display group 004 - base functions: Read measured value block 4 K Readout in display:...
Page 45: Reading Measured Value Block: Display Groups 011 To 055
OCTAVIA Self-Diagnosis Reading measured value block: display groups 011 to 055 Display group 011 - ignition: Read measured value block 11 K Readout in display: → 75...105 -45...105 0...12 °C °C BTDC Ignition angle (actual value) Intake air temperature Coolant temperature Idling speed ⇒...
Page 46 OCTAVIA Self-Diagnosis Display group 026 - knock control, knock sensor voltages: Read measured value block 26 K Readout in display: → 0.2...2.0 0.2...2.0 0.2...2.0 0.2...2.0 Knock sensor voltage signal cyl. 4 Knock sensor voltage signal cyl. 3 Knock sensor voltage signal cyl. 2 Knock sensor voltage signal cyl.
Page 47 OCTAVIA Self-Diagnosis Display group 031 - lambda probe voltages: Read measured value block 31 K Readout in display: → 0.0...1.0 X.XX Vacant Vacant Ignore readout Lambda probe voltage Display group 033 - lambda control value: Read measured value block 33 K Readout in display: →...
Page 48 ∠ ⇒ OCTAVIA Self-Diagnosis Display group 054 - idling speed positioner/switch of electronic throttle systems: Read measured value block 54 K Readout in display: → Text ⇒ °) Ignore readout Sender 1 for accelerator pedal position ⇒ Operating state (idling, enrichment, part load, full load, fuel shut-off on overrun) Idling speed page 01-35, display group number 001 Display group 055 - idling speed stabilisation:...
Page 49: Servicing Fuel Injection System
OCTAVIA Fuel Formation/Fuel Injection Servicing fuel injection sys- Safety precautions Warning! The fuel system is pressurized! Place cleaning rags around the connection point before detaching hose connections or opening the test connection (for measuring fuel pressure). Then, release pressure by carefully detaching the hose or the cap. Pay attention to the following points in order to avoid injuries to persons and/or damage to the fuel injection and ignition system:...
Page 52 OCTAVIA Fuel Formation/Fuel Injection 7 - Engine speed sender -G28- 11 - Injectors -N30- to -N33- 8 - Ignition unit (ignition transformer with 12 - Fuel pressure regulator power output stage) -N152- 13 - Activated charcoal filter solenoid valve 9 - Camshaft position sensor -G163- -N80- 10 - PAS pressure switch -F88- ♦...
Page 53 OCTAVIA Fuel Formation/Fuel Injection K Fig. 1 Fitting location of 4-pin plug con- nection for lambda probe and lambda probe heater The 4-pin plug connection for lambda probe 1 -G39- and lambda probe heater -Z19- is acces- sible after unscrewing the protective cover -ar- rows- at the vehicle floor.
Page 54 OCTAVIA Fuel Formation/Fuel Injection K Fig. 3 Fitting location of electronic throt- tle control fault lamp -K132- K Fig. 4 Fitting location of power steering pressure switch -F88- ¡ ¢ £ ------------ ------------ Edition 07.99 S00.5126.50.20...
Page 56 ¤ ¥ ¦ § ¨ © © © ¥ ¥ ¦ § OCTAVIA Fuel Formation/Fuel Injection injection ! " # $ % & $ ' ( ) $ 0 1 ) 2 3 $ & 0 " 4 5 6 ! A ! "...
Page 57 OCTAVIA Fuel Formation/Fuel Injection 6 - Inlet connection with control flap 14 - 4-pin plug connection ♦ For lambda probe and lambda probe 7 - Inlet hose heater ♦ On right of vehicle floor next to lambda 8 - 8 Nm probe below a cover 9 - Inlet connection 15 - Intake manifold...
Page 60 OCTAVIA Fuel Formation/Fuel Injection K Fig. 1 Resistances for coolant tempera- ture sender -G62- The range A indicates the resistances for the tem- perature range 0...50 °C, range B the resistances for the temperature range 50...100 °C. Examples of how to read chart: ♦...
Page 61 OCTAVIA Fuel Formation/Fuel Injection ♦ Refer to the particular test procedure to de- termine whether the control unit is connected to the test box or not. ♦ Always use adapter cable set V.A.G 1594 A for connecting test equipment (e.g. voltage tester V.A.G 1527 B, hand-held multimeter V.A.G 1526 A etc.).
Page 62: Replacing Engine Control Unit
OCTAVIA Fuel Formation/Fuel Injection Replacing engine control unit Note: When the connectors are unplugged from the engine control unit, the learned values are erased although the contents of the fault memory are retained. Removing Switch off the ignition. Unscrew the windscreen wiper arms and remove the cover of the plenum chamber.
Page 63: Testing Idling Speed
OCTAVIA Fuel Formation/Fuel Injection Testing idling speed Special tools, testers and aids required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Test requirements: l No leak in exhaust system. l Coolant temperature at least 80 °C. l Electrical components switched off (radiator fan must not cut in during the test).
Page 64 → OCTAVIA Fuel Formation/Fuel Injection Enter „056“ for „Display group number 056“ and confirm the entry with the key Q. System in basic setting 56 K Readout in display: 780 rpm 800 rpm 2.5 % 00000 Check whether the engine speed in display block 1 (actual engine speed) is within the permissible tolerance range of display block 2 (specified engine speed).
Page 65: Testing Operating States Of Engine
OCTAVIA Fuel Formation/Fuel Injection Testing operating states of engine Note: What is tested is whether the engine control unit (J361) detects the operating states of the en- gine. Special tools, testers and aids required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Test condition l Coolant temperature must be at least 80 °C.
Page 66 → OCTAVIA Fuel Formation/Fuel Injection Read measured value block 5 K Readout in display: 780 rpm 99 % 0 km/h Idling (1...4 = display blocks) Operating state of engine (display block 4): ♦ Idling: „Idling“ must appear in display block 4 in the idling speed mode.
Page 67 OCTAVIA Fuel Formation/Fuel Injection If the specifications are not achieved: Interrogate the fault memory, rectify any faults ¥ ¦ § ¨ © ¦ § § ¦ present and then erase the fault memory © ¦...
Page 70: Testing Intake System For Leaks (Unmetered Air)
OCTAVIA Fuel Formation/Fuel Injection Testing intake system for leaks (unmetered air) Special tools, testers and aids required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 ♦ Engine leak detection spray G 001 800 A1 Test procedure Notes: ♦ As a result of the vacuum in the intake sys- tem, the leak detection spray is inducted to- gether with the unmetered air.
Page 71: Testing Injectors
OCTAVIA Fuel Formation/Fuel Injection Testing injectors Testing actuation Special tools, testers and aids required ♦ Test box V.A.G 1598/31 ♦ Hand-held multimeter (e.g. V.A.G 1526 A) ♦ Diode test lamp (e.g. V.A.G 1527 B) ♦ Adapter cable set (e.g. V.A.G 1594 A) ♦...
Page 72 OCTAVIA Fuel Formation/Fuel Injection Operate the starter. The LED must flicker. Repeat the test at the connectors of the in- jectors of cylinders 2...4. If the LED does not flicker: Switch off ignition. Connect test box V.A.G 1598/31 to the wir- ing loom to the engine control unit ⇒...
Page 73: Testing Injected Quantity, Leaktightness And Spray Pattern Of Injectors
OCTAVIA Fuel Formation/Fuel Injection Testing resistances of injectors Test the resistance of the injectors between the contacts. Specification: 14...20 Ω If the specification is not achieved: Replace injector(s). Testing injected quantity, leaktightness and spray pattern of injectors Special tools, testers and aids required ♦...
Page 74 OCTAVIA Fuel Formation/Fuel Injection Testing injected quantity Hold the injector to be tested in a measuring glass of the injected quantity tester V.A.G 1602. Connect one contact of the injector with the test cable and a crocodile clamp from V.A.G 1594 A to engine earth.
Page 75: Testing Fuel Pump Relay -J17 And Actuation
OCTAVIA Fuel Formation/Fuel Injection Testing fuel pump relay -J17 and actuation The voltage for the fuel pump and several com- ponents of the fuel injection system is supplied through the fuel pump relay -J17. The engine must be running if the fuel pump relay -J17 is to close.
Page 76 OCTAVIA Fuel Formation/Fuel Injection If the fuel pump does not run: Test voltage supply for fuel pump and com- ponents (through fuel pump relay) ⇒ page 24-27. Testing actuation of fuel pump relay Switch off the ignition. Connect test box V.A.G 1598/31 to the wir- ing loom to the engine control unit ⇒...
Page 77 OCTAVIA Fuel Formation/Fuel Injection Test the following cable connection for open circuit and for short circuit to earth and to positive: Micro electrical centre in Test box V.A.G 1598/31 driver footwell on left, Socket plug position 4 Contact Rectify any open circuit or short circuit in the wiring.
Page 78 ¥ ¦ § ¨ © OCTAVIA Fuel Formation/Fuel Injection intake manifold pressure sender (G71) Special tools, testers and aids required ♦ Hand-held multimeter (e.g. V.A.G 1526 A) ♦...
Page 85 OCTAVIA Fuel Formation/Fuel Injection ⇒ 4-pin connector at wiring Test box V.A.G 1598/31, loom, contact socket Cable resistance: max. 1.5 Ω. Rectify any open circuit in the wiring or short circuit. If no fault is found in the wiring: Replace engine control unit page 24-14.
Page 87: Adapting Engine Electronics Control Unit To Electronic Immobiliser
OCTAVIA Fuel Formation/Fuel Injection Press keys 0 and 6 for the function „End output“ and confirm the entry with the key Q. If the readout varies, or if the battery voltage is not achieved: Switch off the ignition. Connect test box V.A.G 1598/31 to the wir- ing loom to the engine control unit ⇒...
Page 88 OCTAVIA Fuel Formation/Fuel Injection Switch on the ignition. Press keys 1 and 7 for the address word „Dash panel insert“ and confirm the entry with the key Q. Press the → key. K Readout in display: 8L0919860 AB-COMBIINSTR → Coding XXXXX WSC 00000 Press the →...
Page 89: Testing Lambda Control
OCTAVIA Fuel Formation/Fuel Injection Testing lambda control Function of lambda control Notes: The lambda probe compares the oxygen con- tent of the air with the residual oxygen content in the exhaust and supplies a voltage signal to the control unit. The „rich mixture (low level of residual oxygen)“...
Page 90 OCTAVIA Fuel Formation/Fuel Injection ♦ Lambda control switched off (engine control unit has detected a fault at the fuel injection system ⇒ Interrogating fault memory and also Reading measured value block, display group 030). ♦ Probe has been damaged by oil elements escaping from the crankcase ventilation, or by leaks in the engine.
Page 91 OCTAVIA Fuel Formation/Fuel Injection Test procedure Connect vehicle system tester V.A.G 1552 → and select engine electronics (address word 01); engine idling for this step ⇒ page 01-2. K Readout in display: Test of vehicle systems HELP Select function XX Press keys 0 and 8 for the function „Read measured value block“...
Page 92 OCTAVIA Fuel Formation/Fuel Injection Testing lambda probe control Press the key C. Enter „033“ for „Display group number 033“ and confirm the entry with the key Q. Read measured value block 33 K Readout in display: -3.5 % 0.2 V Check the lambda control in display block 1: Specification for display block 1: The readout must vary by at least 2 % within...
Page 93 OCTAVIA Fuel Formation/Fuel Injection Analysis of display group 031 Display block: 1 Possible cause of fault Rectifying fault constant ♦ Large quantity of unmetered air - Test intake system for leaks (unmetered 0.00...0.30 V air) ⇒ page 24-22. poss. constant ♦...
Page 94 OCTAVIA Fuel Formation/Fuel Injection Testing basic voltage Separate the 4-pin plug connection to the lambda probe. Connect the multimeter for voltage measure- ment between contacts 3 and 4. Switch on the ignition. ♦ Specification: 0.400 ... 0.500 V Switch off the ignition. If the specification is not achieved: Test the lambda probe cables ⇒...
Page 95: Testing Lambda Probe Heater
OCTAVIA Fuel Formation/Fuel Injection Testing lambda probe heater The heating circuit of the lambda probe is moni- tored by the self-diagnosis. Interrogating fault memory ⇒ page 01-4. Special tools, testers and aids required ♦ Test box V.A.G 1598/31 ♦ Hand-held multimeter (e.g. V.A.G 1526 A) ♦...
Page 96 OCTAVIA Fuel Formation/Fuel Injection Testing voltage supply Use the adapter cables from V.A.G 1594 A to connect the multimeter for voltage meas- urement to contacts 1+2 of the connector. Start the engine and measure the voltage. Specification: approx. battery voltage Switch off the ignition.
Page 97: Testing Solenoid Valve 1 For Activated Charcoal Filter
OCTAVIA Fuel Formation/Fuel Injection Testing fuel tank breather Testing solenoid valve 1 for acti- vated charcoal filter Special tools, testers and aids required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 ♦ Hand-held multimeter (e.g. V.A.G 1526 A) ♦...
Page 98 OCTAVIA Fuel Formation/Fuel Injection Testing voltage supply of ACF valve Note: The voltage for the ACF valve is supplied through the fuel pump relay. Test condition K l Fuse 43 o.k. Test procedure Unplug the connector at the ACF valve. Connect the diode test lamp between con- tact 1 of the connector and engine earth.
Page 99 OCTAVIA Fuel Formation/Fuel Injection Connect the test box V.A.G 1598/31 to the wiring loom to the engine control unit ⇒ page 24-12. If the diode test lamp came on and remained on, test the cable from contact 2 of the con- nector at the ACF valve to socket 61 of the test box for short to earth.
Page 100: Testing Electronic Power Control (Electronic Throttle)
OCTAVIA Fuel Formation/Fuel Injection Testing electronic power con- trol (electronic throttle) Function of electronic throttle sys- In the electronic throttle system, the throttle valve is not operated by a cable from the accelerator pedal. There is no mechanical link between the accelerator pedal and the throttle valve.
Page 101 OCTAVIA Fuel Formation/Fuel Injection It would be incorrect to believe that the elec- tronic throttle system consists of only one or two components. Rather, the electronic throttle is a system which embraces all the components which contribute to determining the position of the throttle valve, to controlling and monitoring it (e.g.
Page 102 OCTAVIA Fuel Formation/Fuel Injection Testing fault lamp for electronic throttle control -K132 Note: The fault lamp for electronic throttle control -K132 is also known as the EPC warning lamp. Special tools, testers and aids required ♦ Adapter cable set (e.g. V.A.G 1594 A) ♦...
Page 103 OCTAVIA Fuel Formation/Fuel Injection Test the following cable connection for open circuit and short circuit to positive: Test box V.A.G Dash panel insert 1598/31 Socket Contact ⇒ „Current Flow Diagrams, Electrical Fault Finding and Fitting Locations“ binder Rectify any open circuit or short circuit in the wiring.
Page 104 ¤ ¥ ¦ § ¨ © ¦ ¦ ¤ ¤ ¦ OCTAVIA Fuel Formation/Fuel Injection control unit The following components are integrated in the housing of the throttle valve control unit: ♦...
Page 105 OCTAVIA Fuel Formation/Fuel Injection The learning process (adaptation) is performed: ♦ by initiating the basic setting (function 04) display group 60, ignition on. ♦ automatically, if the ignition is switched on for at least about 6 seconds, without operat- ing the starter and accelerator pedal, and the engine control unit detects „learning de- mand“.
Page 106 OCTAVIA Fuel Formation/Fuel Injection Basic setting HELP K Readout in display: Enter display group number XXX Enter 060 for display group number 60 and confirm the entry with the key Q. After pressing the key Q, the throttle valve positioner is first of all de-energized. In this state, the throttle valve is pulled into an emergency running position by a mechanical spring integrated in the throttle valve control unit.
Page 107 OCTAVIA Fuel Formation/Fuel Injection Note: If adaptation is aborted by the control unit, the reasons for this may be as follows: ♦ The throttle valve is not able to close fully (e.g. dirt). ♦ The battery voltage is too low. →...
Page 108 OCTAVIA Fuel Formation/Fuel Injection → Test of vehicle systems HELP K Readout in display: Select function XX Press the keys 0 and 8 for the function „Read measured value block“ and confirm the en- try with the key Q. Read measured value block K Readout in display: Enter display group number XXX Press the keys 0, 6 and 2 for „Display group...
Page 109 ¥ ¦ § ¨ © ¨ ¦ ¨ ! ¨ ¨ ¦ ¦ § OCTAVIA Fuel Formation/Fuel Injection If the readouts do not appear as described: Test the voltage supply and the cable con- nections of the throttle valve control unit ⇒ page 24-61.
Page 113: Testing Additional Signals
OCTAVIA Fuel Formation/Fuel Injection Testing additional signals Testing engine speed signal Notes: ♦ The signal is generated by the engine speed sender -G28-, processed in the engine con- trol unit and passed on by contact 22 of the engine control unit to the dash panel insert as a rev counter signal.
Page 115: Testing Brake Light Switch -F And Brake Pedal Switch -F47
OCTAVIA Fuel Formation/Fuel Injection Connect test box V.A.G 1598/31 to the wir- ing loom to the engine control unit ⇒ page 24-12. Connect the diode test lamp to socket 3 (positive) and socket 9 (vehicle speed sig- nal) of test box V.A.G 1598/31. Switch on the ignition and rotate the left front wheel by hand.
Page 116 OCTAVIA Fuel Formation/Fuel Injection Note: ! ! " # $ % ¥ ¦ § ¨ © ¦ ¦ ¦ ¦ The command from the accelerator pedal posi- ( $ ¨...
Page 118 OCTAVIA Fuel Formation/Fuel Injection ¥ ¦ § ¨ © If the LED does not come on: Test the cable connection from contact 1 or 2, respectively, of the connector for open cir- cuit and for short circuit to earth: ⇒...
Page 119 ¥ ¦ § ¨ ¥ © ¦ ¨ ¥ © ! " # $ % & ' OCTAVIA Fuel Formation/Fuel Injection Testing tools, testers and aids required ♦ Hand-held multimeter (e.g. V.A.G 1526 A) ( ) "...
Page 122 OCTAVIA Fuel Formation/Fuel Injection ¤ ¥ ¦ § ¨ © § ¦ ¥ Read measured value block 56 K Readout in display: → 780 rpm 800 rpm 25 % 00000 Check the readout for the power steering pressure switch in display block 4.
Page 123: Testing Databus (Can Bus)
OCTAVIA Fuel Formation/Fuel Injection Test the following cable connections for open circuit and for short circuit to earth and to positive: Contact at plug Test box V.A.G 1598/31, connection socket Rectify any open circuit in the wiring or short circuit. Testing databus (CAN databus) 1 - Engine control unit ♦...
Page 124 OCTAVIA Fuel Formation/Fuel Injection Information which is not supplied over the da- tabus, is recognised both by the engine control unit -1- as well as by other CAN databus control units as a fault (e.g. ABS control unit -2-). A terminating resistor R must be positioned up- stream of the bus driver -3- in both control units to enable the CAN databus to operate properly.
Page 127: Testing Ignition System
OCTAVIA Ignition System Testing ignition system General information on the ignition system ♦ The engine control unit is equipped with self- diagnosis. ♦ A voltage of at least 11 V is required for proper operation of the electrical compo- nents. ♦...
Page 128: Setting Data Of Spark Plugs
OCTAVIA Ignition System Setting data, spark plugs Engine Idling speed 730 to 870 rpm Speed cannot be adjusted, is controlled by idling speed stabilisation Engine speed governed approx. 5800 rpm by shutting off injectors Ignition timing cannot be adjusted, is determined by the engine control unit Firing order 1 - 3 - 4 - 2 Spark plugs...
Page 130: Testing Ignition Coils With Power Output Stage
OCTAVIA Ignition System Testing ignition coils with power output stage Special tools, testers and aids required ♦ Hand-held multimeter (e.g. V.A.G 1526 A) ♦ 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 1598/31 ♦...
Page 131 OCTAVIA Ignition System Testing actuation Warning! When conducting the following test, do not touch the connection parts of the ignition coils or the test cables. Unplug the connectors from the injectors Unplug the 4-pin connector from the power output stage for the ignition coils. Use adapter cables from V.A.G 1594 A to connect the diode test lamp to contacts 1 + 4 (ignition output 1),...
Page 132: Testing Camshaft Position Sensor -G163
OCTAVIA Ignition System Testing camshaft position sensor -G163 Note: The camshaft position sensor -G163- is identi- cal with the Hall sender -G40-. Special tools, testers and aids required ♦ Hand-held multimeter (e.g. V.A.G 1526 A) ♦ Adapter cable set (e.g. V.A.G 1594 A) ♦...

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