Skoda OCTAVIA Workshop Manual
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Skoda OCTAVIA Workshop Manual

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Service
Workshop Manual
OCTAVIA
1.9-ltr./81 kW (TDI) Engine,
Fuel Injection and Glow Plug System
Service Department. Technical Information
S00.5122.50.20 Edition 03.98

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Summary of Contents for Skoda OCTAVIA

  • Page 1 Service Workshop Manual OCTAVIA 1.9-ltr./81 kW (TDI) Engine, Fuel Injection and Glow Plug System Service Department. Technical Information S00.5122.50.20 Edition 03.98...
  • 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 © 1998 ŠKODA AUTO a. s.
  • Page 3 Service List of Supplements to Workshop Manual Edition: 01.04 OCTAVIA 1.9l/81 kW (TDI) Engine, Fuel Injection and Glow Plug System Replaces List of Supplements - Edition: 10.03 Subject Edition Article Number Supple- ment 03.98 Basic Edition S00.5122.50.20 02.99 Modifications to Fault Codes S00.5122.51.20...

  • Page 5: Table Of Contents

    OCTAVIA Service Contents Self-Diagnosis Page Self-Diagnosis ..........................01-1 Properties of the self-diagnosis ....................01-1 Technical data of self-diagnosis ....................01-1 Connecting tester V.A.G 1552 and select engine electronics control unit ........ 01-2 Interrogating and erasing fault memory ..................01-5 Fault table ..........................
  • Page 6 Service OCTAVIA Testing injection control ......................Testing injection timing device control range ................Testing the commencement of injection valve (N108) ............. Inspecting fuel temperature sender ..................Inspecting exhaust gas recirculation system ................Hose layout plan for the charge pressure regulation, the exhaust gas recirculation and intake manifold flap ........................

  • Page 7: Self-Diagnosis

    OCTAVIA Self-Diagnosis Self-Diagnosis Properties of the self-diagnosis The control unit for the diesel direct injection sys- tem is equipped with a fault memory. The fault memory is designed as a permanent memory and as a volatile memory. If malfunctions occur in the monitored sensors or components, they are stored in the fault me- mory with indication of the fault type.
  • Page 8 OCTAVIA Self-Diagnosis Available functions when using vehicle sys- tem tester V.A.G 1552 Please refer to the table below for the require- ments when you wish to select the desired func- tions. Function Requirement Engine off, Engine ignition idling switched on...
  • Page 9 OCTAVIA Self-Diagnosis Procedure Connect the vehicle system tester V.A.G 1552 with the cable V.A.G 1551/3. After the vehicle system tester has been con- nected: Depending on the function you desire, you have to: Switch on the ignition or start the engine ⇒...
  • Page 10 OCTAVIA Self-Diagnosis 038906018.. 1.9 l R4 EDC G00SG 1816 K The control unit identification appears in the dis- → Coding 00002 WSC 01234 play, e.g.: ♦ 038906018.. Part no. of control unit part (for current control unit ver- sion - spare parts catalogue) ♦...

  • Page 11: Interrogating And Erasing Fault Memory

    OCTAVIA Self-Diagnosis ♦ Functions not being performed ♦ Reduction in gearbox life If the coding does not match the corresponding version in the vehicle: Check coding of engine control unit page 01-26, Coding engine control unit. Press → key. Test of vehicle systems...
  • Page 12 Self-Diagnosis OCTAV1A If one or several faults are stored: → Press key. K Read-out of fault number on display, e.g.: → Fault number: 00542 → Press key. Needle lift sender -G80 K Fault source and fault type appear in the dis- →...
  • Page 13 OCTAVIA Self-Diagnosis Test of vehicle systems HELP K Readout in display: Select function XX Enter 02 for the function „Interrogate fault memory“ and confirm the entry with the key K The number of stored faults appears in the dis- X faults recognized! play.

  • Page 14: Fault Table

    OCTAVIA Self-Diagnosis Fault table Notes: ♦ For vehicles 08.98 ä, different fault codes Operating instructions for vehicle system with the same or similar texts are displayed. tester The required text is to be selected in the fault ♦ If components are output as faulty: table according to the fault code.
  • Page 15 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 00522 17663 Coolant temperature sender -G62 Short circuit to ♦ -G62 faulty ♦ Black exhaust when start- - Test coolant temperature earth ♦ Cable has short circuit to...
  • Page 16 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 00532 18008 Supply voltage Implausible signal ♦ Control unit was con- - Erase fault memory and nected when ignition on continue checking vehicle as appropriate ♦...
  • Page 17 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 00542 17653 Needle lift sender -G80 Short circuit to ♦ -G80 faulty ♦ Glow indicator lamp - Test needle lift sender earth ♦ Open circuit in wiring or flashes 1.9-ltr./66 kW (TDI) En-...
  • Page 18 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 00550 17656 Commencement of injection control Control difference ♦ Commencement of deliv- ♦ Poor performance at higher - Test and set commence- ery not o.k.
  • Page 19 Self-Diagnosis OCTAV1A Readout V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 00553 16485 Air mass meter -G70 Implausible sig- ♦ The engine was stalled - Erase fault memory, ob- (within the last 50 engine serve vehicle again starts) ♦...
  • Page 20 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 00625 16885 Speed signal implausible sig- ♦ Open circuit in wiring be- ♦ CCS not operating - Test vehicle speed signal tween speedometer sender ♦...
  • Page 21 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 00741 Brake pedal monitor- Implausible signal ♦ Switch incorrectly set ♦ Preglow indicator lamp - Test -F and -F47 and set ♦ Open circuit in wiring flashes 1.9-ltr./66 kW (TDI) En-...
  • Page 22 Self-Diagnosis OCTAV1A Readout V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 01028 Blower relay -J323 Line interrup- ♦ Line interruption of ♦ Delayed fan switch off - Check radiator fan signal tion/short-circuit ♦ Relay -J323 defective ⇒...
  • Page 23 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 19460 01193 Low heating capac- ity relay -J359 open circuit/short ♦ Open circuit in wiring ♦ Engine preheating not op- - Test cable connections...
  • Page 24 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 01262 17954 Charge pressure con- trol solenoid valve -N75 Short circuit to posi- ♦ Short circuit to positive ♦ Reduced output - Test charge pressure con- tive ♦...
  • Page 25 OCTAVIA Self-Diagnosis on V.A.G 1552 Possible Possible effects Control differ- ♦ Injection pump faulty ♦ Poor drivability - Test quantity adjuster ence (variation) ♦ Open circuit in wiring or ♦ Engine switches off -N146 page 23-13 short circuit ♦ Glow plug indicator light...
  • Page 26 Self-Diagnosis OCTAV1A Readout V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 16500 Coolant tempera- ture sender -G62 Implausible sig- ♦ Sender for coolant tem- ♦ Cold-start difficulties at - Reading measured value perature -G62 supplies very low temperatures block, display group 007 implausible signal caused ♦...
  • Page 27 Self-Diagnosis OCTAV1A Readout V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 17931 Crash signal of airbag CU Implausible sig- ♦ Fault in airbag system ♦ Airbag warning light comes - Check airbag ⇒ Body Work; Repair Group 17964 Charge pressure control...
  • Page 28 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number of fault ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ------------ ------------ Edition 01.02 S00.5122.53.20...
  • Page 29 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number of fault 18058 Drive train databus no message ♦ Datalines faulty ♦ Poor driving characteris- - Test databus from instrument ♦ Incorrect or faulty dash tics 1.9-ltr./66 kW (TDI) En- cluster panel insert gine, Fuel Injection and ♦...
  • Page 30 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number of fault ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ------------ ------------ Edition 01.02 S00.5122.53.20...
  • Page 31 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number of fault ♦ ♦ ♦ ♦ Edition 01.02 ------------ ------------ S00.5122.53.20...

  • Page 32: Actuator Diagnosis

    OCTAVIA Self-Diagnosis Actuator diagnosis Performing actuator diagnosis With the actuator diagnosis the following parts are activated in the sequence indicated: 1. Commencement of injection valve (N108) 2. Exhaust gas recirculation valve (N18) 3. AC compressor engagement 4. Fuel shut-off valve (N109) 5.
  • Page 33 OCTAVIA Self-Diagnosis Press keys 0 and 3 for the function „Final control diagnosis“. Test of vehicle systems K Readout in display: 03 - Final control diagnosis Confirm the entry with the key Q. Final control diagnosis K Readout in display:...
  • Page 34 OCTAVIA Self-Diagnosis → Press key. Actuator diagnosis K Read-out on display: → Fuel shut-off valve -N109 The engine must stop. If the engine does not stop: Switch off ignition. Unscrew fuel shut-off valve and remove pos- sible swarf and dirt.
  • Page 35 OCTAVIA Self-Diagnosis → Press key. Actuator diagnosis K Read-out on display: → Low heat output relay -J359 The relay valve must click. If the relay does not click: Check low heat output relay: Binder: Current Flow Diagrams, Electrical Fault Finding and Fitting locations.

  • Page 36: Basic Setting

    OCTAVIA Self-Diagnosis Basic setting Test conditions l Coolant temperature at least 80 °C l Electrical components switched off (radiator fan must not cut in during the test) l AC switched off Special tools, testers and aids required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3...
  • Page 37 OCTAVIA Self-Diagnosis Display group 000 at idling speed (engine warm, coolant temperature not below +80 °C) This display group is used for the dynamic test of the commencement of injection. The commencement of injection valve (N108) is constantly actuated as a result of which the injection timing control is „retarded“.
  • Page 38 OCTAVIA Self-Diagnosis If the coding displayed does not match the ve- hicle, or if the control unit has been replaced, it is then necessary to code the control unit as follows. and aids ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C...

  • Page 39: Readiness Code

    Self-Diagnosis OCTAV1A Readiness code Valid for vehicles 08.03 ä Reading readiness code Function The readiness codes are two 8-digit numerical codes which indicate the status of the emission-relevant diagnoses. If the diagnosis for a system was successfully performed (e.g. exhaust gas recirculation sys- tem), the relevant position of the numerical code is set from 1 to 0.
  • Page 40 Self-Diagnosis OCTAV1A Meaning of 8-digit numerical block for readiness code in display field 2 Meaning Ignore Ignore Ignore Ignore Ignore Diagnosis of other systems Diagnosis of fuel supply Ignore Meaning of 8-digit numerical block for readiness code in display field 4 Meaning Ignore Ignore...

  • Page 41: Generate Readiness Code

    Self-Diagnosis OCTAV1A Generating readiness code Special tools, aids and testers required ♦ Vehicle system tester -V.A.G 1552- with ca- ble -V.A.G 1551/3, 3A, 3B or 3C- Test conditions l All electrical consumers such as e.g. light and rear window heater must be switched off.
  • Page 42 Self-Diagnosis OCTAV1A Work step 3: Switching off ignition Wait at least 5 seconds with ignition OFF. Note: This point is important, because with certain di- agnoses the slowing down of the control unit must be ended. Otherwise readiness code can- not be generated.
  • Page 43 Self-Diagnosis OCTAV1A Work step 10: 2nd test of exhaust gas re- circulation Increase engine speed to 1600 rpm up to Reading measured value block 1650/rpm → 4.1 mg/h 2.0 °CA 93.2 °C 1700 rpm and maintain it for at least 10 sec- onds in this range.
  • Page 44 Self-Diagnosis OCTAV1A Edition 01.04 ------------ 01-30.2 ------------- S00.5122.55.20...

  • Page 45: Measured Value Blocks

    OCTAVIA Self-Diagnosis Measured value blocks Reading measured value block Test conditions l Coolant temperature at least 80 °C l Electrical consumers must be disconnected (the radiator cooling fan must be off during this test) l Air conditioning switched off l No fault in fault memory Special tools, aids and testers required ♦...
  • Page 46 OCTAVIA Self-Diagnosis Specified readouts for general vehicle check Display group 000, engine idling (engine warm, coolant temperature not below +80 °C) 04.99 for models ä Read measured value block K Readout in display → 153 127 Inducted air mass : 69...111 o.k.
  • Page 47 OCTAVIA Self-Diagnosis Display group 000, engine idling (engine warm, coolant temperature not below +80 °C) 05.99 for models ä Read measured value block K Readout in display → 153 127 Inducted air mass : 69...110 o.k. • if not to tolerance page 01-47, display group 003 Fuel temperature: 91...201...
  • Page 48 OCTAVIA Self-Diagnosis group 000 at full test in gear, +80 °C, engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ The measured values must be read off or printed out (second person required) once an engine speed of 3000 rpm has been reached.
  • Page 49 OCTAVIA Self-Diagnosis Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not below +80 °C, engine 05.99 speed 2900...3100 rpm) for models ä Notes: ♦ Accelerate the vehicle at full throttle for the test.
  • Page 50 OCTAVIA Self-Diagnosis Specified readouts for injection pump Display group 001, engine idling (engine warm, coolant temperature not below +80 °C) 04.99 for models ä Read measured value block K Readout in display → 900 rpm 5.6 mg/s 1.480 V 87.3 °C Coolant temperature •...
  • Page 51 OCTAVIA Self-Diagnosis Display group 001, engine idling (engine warm, coolant temperature not below +80 °C) 05.99 for models ä Read measured value block K Readout in display → 900 rpm 5.6 mg/s °C Coolant temperature 10 °C o.k., < °C: warm up engine •...
  • Page 52 OCTAVIA Self-Diagnosis Read measured value block K Readout in display → temperature piston movement sender to control unit position • V rises in time closed • display block only replace pump pump by control rises in time • or constant system •...
  • Page 53 OCTAVIA Self-Diagnosis Display group engine idling Read measured value block K Readout in display → 900 rpm ratio commencement valve • commencement • commencement blocked • valve control pump stops too late test commencement and set • too cold valve...
  • Page 54 OCTAVIA Self-Diagnosis group at full test in gear engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ The measured values must be read off or printed out (second person required) once an engine speed of 3000 rpm has been reached.
  • Page 55 OCTAVIA Self-Diagnosis Display group at full test in gear 05.99 engine speed ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ The measured values must be read off or printed out (second person required) once an engine speed of 3000 rpm has been reached.
  • Page 56 OCTAVIA Self-Diagnosis Specified readouts for engine idling group engine idling coolant t Read measured value block K Readout in display → 900 rpm temperature • • state able states pedal position • accelerator pedal position sender incorrectly set or •...
  • Page 57 OCTAVIA Self-Diagnosis Display group ignition Read measured value block K Readout in display → operating state page operating state page pedal monitor page pedal monitor ignore pedal Display pedal display positions = 1 pedal and brake pedal not depressed pedal depressed...
  • Page 58 OCTAVIA Self-Diagnosis state state Model with CCS - CCS switched off Model with CCS - CCS switched on 2 5 5 Model without CCS, CCS function may not be activated in engine control unit ------------ ------------ Edition 02.01 S00.5122.52.20...
  • Page 59 OCTAVIA Self-Diagnosis Display group engine idling Read measured value block → able able load able additional Meaning of the digits in the 8-digit numerical block for ad- ditional heater: if display readouts less less ä 05.99 ä less able elements...
  • Page 60 OCTAVIA Self-Diagnosis Display group 013, engine idling (engine warm, coolant temperature not less than +80 °C) ♦ The fuel injection system features a smooth idling speed control. It is possible to detect performance differences between the individual cylinders (parts tolerances, injector flow, compression, etc.) and to compensate for this in the idling speed range by selective metering of the quantity of fuel injected.
  • Page 61 OCTAVIA Self-Diagnosis Specified readouts for exhaust gas recirculation Display group 003, engine idling (engine warm, coolant temperature not less than +80 °C) Read measured value block K Readout in display → 900 rpm 290 mg/s 308 mg/s 54 % On/off ratio (actuation) of exhaust gas recirculation valve •...
  • Page 62 OCTAVIA Self-Diagnosis readouts for senders Read measured value block K Readout in display → temperature coolant temperature sender open circuit in temperature • is displayed as substitute value temperature intake temperature sender open circuit in constant is displayed as substitute value •...
  • Page 63 OCTAVIA Self-Diagnosis Specified readouts for group at full throttle (road test in gear coolant t engine speed ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ The measured values must be read off or printed out (second person required) once an engine speed of 3000 rpm has been reached.
  • Page 64 OCTAVIA Self-Diagnosis Display group at full (road test in gear engine 05.99 ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ The measured values must be read off or printed out (second person required) once an engine speed of 3000 rpm has been reached.
  • Page 65 OCTAVIA Self-Diagnosis Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ The measured values must be read off or printed out (second person required) once an engine speed of 3000 rpm has been reached. Read measured value block...
  • Page 66 OCTAVIA Self-Diagnosis Display group 010 at full test in gear coolant engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ The measured values must be read off or printed out (second person required) once an engine speed of 3000 rpm has been reached.
  • Page 67 OCTAVIA Self-Diagnosis group 010 at full test in gear, engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ The measured values must be read off or printed out (second person required) once an engine speed of 3000 rpm has been reached.
  • Page 68 OCTAVIA Self-Diagnosis readouts for pressure group 011 at full (road test in gear engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ The measured values must be read off or printed out (second person required) once an engine speed of 3000 rpm has been reached.
  • Page 69 OCTAVIA Self-Diagnosis group 011 at full test in gear, engine speed ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ The measured values must be read off or printed out (second person required) once an engine speed of 3000 rpm has been reached.

  • Page 71: Rules For Cleanliness

    OCTAVIA Fuel Formation / Fuel Injection Servicing diesel direct injec- tion system Safety precautions Pay attention to the following points to avoid in- juries to persons and/or damage to the fuel in- jection and glow plug system: ♦ Do not disconnect and connect lines or ca-...
  • Page 72 OCTAVIA Fuel Formation / Fuel Injection Summary of fitting locations Components A to F are not shown in the gen- D - Accelerator pedal position sender eral illustration. (G79) ♦ In footwell at accelerator pedal A - Diesel direct injection system relay 1.9-ltr./66 kW (TDI) Engine, Fuel...
  • Page 73 OCTAVIA Fuel Formation / Fuel Injection 3 Connector ♦ With mechanical exhaust gas recir- ♦ 2-pin culation valve ♦ For needle lift sender (G80) ♦ With intake manifold flap 4 Connector ♦ 3-pin ♦ For engine speed sender (G28) 3 Injection nozzle...
  • Page 74 OCTAVIA Fuel Formation/Fuel Injection Testing charge pressure sys- Testing charge pressure Special tools, testers and aids required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C Test conditions l No fault in fault memory l No leaks at inlet and exhaust side...
  • Page 75 OCTAVIA Fuel Formation / Fuel Injection ♦ Operation (linkage, shaft) of the bypass valve stiff or stuck (bypass valve constantly open) ♦ Vacuum unit leaking ♦ Intake manifold pressure sender faulty ♦ Leak between turbocharger and intake mani- fold ♦ Turbocharger faulty (turbine blocked by for-...
  • Page 76 OCTAVIA Fuel Formation/Fuel Injection If the linkage does not move although the charge pressure control solenoid valve operates: Inspect vacuum hoses according to hose diagram ⇒ page 23-9. Test charge pressure control pressure unit ⇒ 1.9 l/66 kW (TDI) Engine - Mechanical Com- ponents;...
  • Page 77 OCTAVIA Fuel Formation/Fuel Injection If the If the ⇒ Edition 02.01 ------------ ------------ S00.5122.52.20...
  • Page 78 OCTAVIA Fuel Formation/Fuel Injection For t K Test the following cable connections for short circuit to positive and to negative, and to open circuit (connector -1-). connector 2, 28 Rectify any open circuit or short circuit in the wiring. For t...
  • Page 79 OCTAVIA Fuel Formation/Fuel Injection Hose diagram for charge pressure control, exhaust gas recirculation and intake manifold flap 1 - Vacuum positioning element for intake manifold flap 2 - Intake manifold flap changeover valve (N239) 3 - Branch 4 - Non-return valve ♦...
  • Page 80 OCTAVIA Fuel Formation/Fuel Injection Testing air mass meter The air mass meter is required by the control unit for calculating the permissible injected quan- tity and for controlling the exhaust gas recircu- lation. The smaller the signal supplied by the air mass meter, the less fuel may be injected.
  • Page 81 OCTAVIA Fuel Formation/Fuel Injection Read measured value block Specification in display block 4: 830 mg/s 1030 mbar 1850 mbar 100 % (accelerator pedal position) If the specification is not achieved: Repeat the test and accelerate vehicle at full throttle. Read measured value block Specification in display block 3: 1850...
  • Page 82 OCTAVIA Fuel Formation/Fuel Injection If the ⇒ connector ä connector If the ⇒ ------------ ------------ Edition 02.01 S00.5122.52.20...
  • Page 83 OCTAVIA Fuel Formation/Fuel Injection connector connector ⇒ Edition 02.01 ------------ ------------ S00.5122.52.20...
  • Page 84 OCTAVIA Fuel Formation/Fuel Injection connector ⇒ ------------ ------------ Edition 02.01 S00.5122.52.20...
  • Page 85 OCTAVIA Fuel Formation/Fuel Injection esting modulating ment sender and adjuster The e testers and aids ♦ ♦ ♦ ♦ T → ä → ä → Edition 02.01 ------------ ------------ S00.5122.52.20...
  • Page 86 OCTAVIA Fuel Formation/Fuel Injection Electrical modulating ment Switch ignition off. Separate plug connection -arrow- from in- jection pump. Connect multimeter for resistance measure- ment to the following contacts of the con- nector -2-. connector 1 + 2 4.9...7.5 Ω 3 + 2 4.9...7.5 Ω...
  • Page 87 OCTAVIA Fuel Formation/Fuel Injection connector connector ⇒ Edition 02.01 ------------ ------------ S00.5122.52.20...

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