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Skoda Octavia 1997 Workshop Manual

2.0 i/85kw engine, fuel injection and ignition systems
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  • Page 3 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System List of Supplements to Workshop Manual OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Edition 02.00 Supple- Edition Subject Article Number ment 02.00 Basic Edition S00.5128.50.20 03.01 Supplement to basic edition (completely replaces the basic edi- S00.5128.51.20...
  • Page 4 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System List of Supplements Edition 01.04 S00.5128.53.20...

  • Page 5: Table Of Contents

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Table of Contents 01 – Self-diagnosis Self-diagnosis I ..................01-1 page - Properties of the self-diagnosis ..............01-1 page - Technical data of self-diagnosis ..............01-1 page - Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics ....................
  • Page 6 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System - Testing voltage supply for engine control unit ............ 24-4 page - Procedure if voltage supply interrupted ............24-4 page - Replacing engine control unit ................ 24-4 page - Code the engine control unit (AEG, APK, AQY) ..........
  • Page 7 2&7$9,$  ©  O N: (QJLQH )XHO ,QMHFWLRQ DQG ,JQLWLRQ 6\VWHP  ± 6HOIGLDJQRVLV  6HOIGLDJQRVLV , 3URSHUWLHV RI WKH VHOIGLDJQRVLV 7KH HQJLQH FRQWURO XQLW FRQWURO XQLW IRU WKH LQMHFWLRQ DQG LJQLWLRQ V\VWHP 0RWURQLF - LV HTXLSSHG ZLWK D IDXOW PHPRU\ ,I PDOIXQFWLRQV RFFXU LQ WKH PRQLWRUHG VHQVRUV RU FRPSR QHQWV WKH\ DUH VWRUHG LQ WKH IDXOW PHPRU\ ZLWK LQGLFDWLRQ...
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  • Page 13: Self-Diagnosis Ii

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 01-2 Self-diagnosis II Fault table, fault codes 16485...17736 Note The fault table is arranged according to the 5-digit fault code on the left. Faults related to the electronic throttle are indicated on the dash panel insert by the fault lamp for the elec- tronic accelerator control „EPC warning lamp“.
  • Page 14 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552 - – 16496 Signal too low Read measured value block, display group 004, display field 4 Intake air temperature Chapter 01-5 sender -G42- –...
  • Page 15 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552 - – 16554 Malfunction Test fuel pressure regulator and holding pressure Chap. 24-2 Bank 1, fuel metering – Test injectors Chapter 01-4, Final control diagnosis system –...
  • Page 16 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552 - 16648 Short circuit to see fault code 16645 Injector cyl. 2 -N31- earth 16649 Short circuit to see fault code 16646 Injector cyl. 2 -N31- positive 16651 Short circuit to...
  • Page 17 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552 - 16725 Implausible Camshaft position sen- signal sender -G40- 16726 Signal too low Camshaft position sen- sender -G40- 16727 Signal too Camshaft position sen- high sender -G40- 16735...
  • Page 18 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552 - – 16894 Malfunction Test throttle valve control unit Chapter 24-2 Idling speed switch – Replace engine control unit Chapter 24-4 -F60- – 16897 incorrect code Adapt engine control unit to electronic immobiliser...
  • Page 19 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552 - – 17510 Short circuit to Testing lambda probe heater upstream of catalytic converter Bank 1 - probe 1, heat- positive Chapter 24-3 ing circuit 17511 Output too...
  • Page 20 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552 - – 17553 Short circuit to Read measured value block, display group 002 Chapter 01-5 Air mass meter -G70- positive – Check wiring to meter -G70- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations 17557...
  • Page 21 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552 - 17592 Open circuit Linear lambda probe/ combined earth cable 17593 Short circuit to Linear lambda probe/ earth combined earth cable 17594 Short circuit to Linear lambda probe/ positive combined earth cable...
  • Page 22 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552 - – 17733 Regulating Inspecting knock sensors -G61- and -G66 - Chap. 28-1. Knock control Cyl. 1 limit reached – Read measured value block, display group 026 Chap.

  • Page 23: Self-Diagnosis Iii

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 01-3 Self-diagnosis III Fault table, fault codes 17743...18101 Readout on Rectifying fault -V.A.G 1552- – 17743 Regulating Inspect vacuum lines for tightness Engine torque monitor- limit exceed- – Inspect intake system for leaks ing 2 –...
  • Page 24 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552- – 17828 Electrical fault Test secondary air injection valve Chapter 01-4, Final control diag- Secondary air injection in the circuit nosis valve -N112- 17829 Short circuit to Secondary air injection...
  • Page 25 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552- 17923 Short circuit to Valve for variable in- earth take manifold changeo- ver -N156- 17924 Open circuit Valve for variable in- take manifold changeo- ver -N156- 17925 Electrical fault...
  • Page 26 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552- – 17977 Implausible Check cruise control system (CCS) in the measured value block, dis- CCS switch -E45- signal play group 066 Chapter 01-7 –...
  • Page 27 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Readout on Rectifying fault -V.A.G 1552- 18041 Signal too low Sender 2 for accelera- tor pedal position -G185- 18042 Signal too Sender 2 for accelera- high tor pedal position -G185- 18044 Missing mes-...
  • Page 28 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Note regarding fault code 17978: The immobilizer control unit is located in the dash panel insert and cannot be replaced individually. When attempting to start with a non-adapted key a static fault is stored in the memory.

  • Page 29: Self-Diagnosis Iv

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 01-4 Self-diagnosis IV Actuator diagnosis With the actuator diagnosis the following parts are acti- vated in the sequence indicated: 1 - Injector cyl. 1 -N30- 2 - Injector cyl. 2 -N31- 3 - Injector cyl.
  • Page 30 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Before repeating final control diagnosis without briefly running the engine in-between, switch the ignition off for about 2 seconds. The electric fuel delivery unit runs during the entire fi- nal control diagnosis.

  • Page 31: Readiness Code

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System – Test activated charcoal filter solenoid valve -N80- and cable connections for open circuit, short circuit to earth and to positive Current Flow Diagrams, Elec- trical Fault Finding and Fitting Locations. Actuate secondary air inlet valve -N112-: Actuator diagnosis ->...

  • Page 32: Reading Readiness Code

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Reading readiness code Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C- Procedure – Connect vehicle system tester -V.A.G 1552-, switch ignition on and enter address word 01 „Engine elec- tronics“...
  • Page 33 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Test conditions • Vehicle stopped • On vehicles with an automatic gearbox the selector le- ver must be in position „P“ or „N“ • All electrical components such as headlights and rear window heater, must be switched off.
  • Page 34 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System – Select function 04 „Initiate basic setting“ and display group 060. System in basic setting 60 -> For engines with engine code AQY x.x V Idling ADP runs ° –...
  • Page 35 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Read-out on the display for engines with engine code: System in basic setting 70 -> xx.x % x.x % xx.x g/s Test ON AZH, AZJ System in basic setting 70 ->...
  • Page 36 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Meaning of 3-digit numerical block in display fields 1 and 2: Meaning if display position Lambda control active Lambda probe operational Lambda probe heater switched on If the specified values are not reached: –...
  • Page 37 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Specification in display field 4: "B1-S1 o.k." If the specified values are not reached: – Interrogate fault memory Chapter 01-1. If the specified values are reached: 8. step: Diagnosis of catalytic converter Note This diagnosis is only ended once the diagnosis of the lambda probe ageing has been successfully completed.
  • Page 38 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 9. step: Reading readiness code – Read readiness code 01-4 page 4. Self-diagnosis IV Edition 01.04 01-4 page S00.5128.53.20...
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  • Page 51: Self-Diagnosis Vi

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 01-6 Self-diagnosis VI Reading measured value block, display groups 030 to 062 Display group 030 - lambda control • Engine idling • Catalytic converter temperature at least 352 °C (display group 034, display field 2) Read measured value block 30 Readout on display Display field...
  • Page 52 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Display group 031, lambda control - lambda values upstream of catalytic converter • Engine idling Read measured value block 31 Readout on display x.xxxx x.xxxx — — Display field Specification Analysis —...
  • Page 53 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System add = additive - The effect of the fault (e.g. unmetered air) becomes increasingly less as engine speed rises. In the case of an additive initialisation value the injec- tion period is changed by a fixed rate.
  • Page 54 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System The readout must in some cases be less than 0.3 V and in some cases more than 0.6 V. The readout be- low 0.45 V indicates a lean mixture while above 0.45 V indicates a rich mixture.
  • Page 55 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Analysis of display groups 032 and 033, display fields 1 and 2 - lambda learned values Readout on -V.A.G 1552 - Rectifying fault low learned values – Disappears after driving on motorway or changing oil –...
  • Page 56 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Display group 034, lambda control - diagnosis of lambda probe upstream of catalytic converter (for engines with the engine codes AQY) • Vehicle stationary, engine running at fast idling •...
  • Page 57 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Note Re display field 3: The dynamic factor is the measure of the status of the lamda probe ageing. The lower the dynamic factor the more advanced the lamda probe ageing. Display group 036, lambda control - operational readiness downstream of catalytic converter (for engines with engine codes AQY, AZJ) •...
  • Page 58 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Analysis of display group 036, display field 1 - lambda probe voltage, lambda probe downstream of catalytic converter Display field: 1 Rectifying fault constant – Testing the intake system for tightness (unmetered air) 0.00..0.30 V –...
  • Page 59 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Note Re display field 3: If the readout rises above 200 ms, there is a leak in the exhaust system. Display group 037, lambda control - operational readiness downstream of catalytic converter (for engines with engine codes AZH, AZJ) •...
  • Page 60 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Note Depending on the operating state of the engine the lamb- da probe heaters are switched on or off, i.e. the readouts in display field 2 and 4 may show either Htg.u(d)C.ON or Htg.u(d)C.OFF.
  • Page 61 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Note Re display field 3: The indicated value for the new catalytic converters should be above 5.00. Display group 050, engine speed control - operating states • Engine idling Read measured value block 50 Readout on display xxxx rpm...
  • Page 62 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Display group 054, engine speed control - operating states • Engine idling • Driving Read measured value block 54 Readout on display xxxx rpm Text ° ° xxx.x % xxx.x % Display field Specification...
  • Page 63 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Meaning of the numerical block display field 4, operating conditions For engines with engine codes AEG, APK, AQY Meaning if display position Air conditioning compressor on Gear engaged, selector lever in 1/2/3/R/D (automatic gearbox) Air conditioning switched on No meaning For engines with engine codes AZH, AZJ...
  • Page 64 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Display group 060 - adjustment of the throttle valve control unit • Ignition switched on, engine switched off • Control unit in function 04 - initiate basic setting System in basic setting 60 Readout on display xx.x V Text...
  • Page 65 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System for engines with engine code AZJ Display group 062 - engine speed control, E-gas (for engines with the engine codes AZH, AZJ) • Ignition on Read measured value block 62 Readout on display xxx % xxx %...
  • Page 66 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Self-diagnosis VI Edition 01.04 01-6 page S00.5128.53.20...
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  • Page 75: 24 - Fuel Formation, Injection

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 24 – Fuel Formation, Injection 24-1 Repairing the injection system General Instructions Special instructions regarding ignition system Chapter 28-1. The engine control unit is equipped with a self-diagno- sis system. Before commencing repairs and also for fault finding, first of all interrogate the fault memory.

  • Page 76: Rules Of Cleanliness

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System If test and measuring devices are required during test drives observe the following: Always secure the test and measuring devices on the rear seat and have a second person operate them there.
  • Page 77 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 1 - Activated charcoal filter sole- */** noid valve -N80- Activated charcoal filter 2.0 l/85 kW Engine, Me- chanical Components; Rep. Gr. 20 2 - Plug connection for lambda probe upstream of catalytic converter for engines with engine iden-...
  • Page 78 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System item 17 in 24-1 page 7 16 - 3-pin plug connection for the engine speed sender -G28- grey 17 - Knock sensor 1 -G61- 18 - Fuel pressure regulator 19 - Camshaft position sensor -G40 - inspect Chapter 28-1...

  • Page 79: Removing And Installing Parts Of The Injection System

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System disassembling and assembling 24-1 page 8 17 - Main fuse box 18 - ignition coil with power output stage (- N70-, -N127-, -N291-, -N292-) 19 - Engine speed sender -G28 - inductive pickup Fitting location: under the oil filter in the cylinder block item 17 in 24-1 page 7...
  • Page 80 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 1 - Top part of intake manifold 2 - from activated charcoal filter solenoid valve -N80- Activated charcoal filter 2.0 l/85 kW Engine, Me- chanical Components; Rep. Gr. 20 3 - Plug connection for engines with engine iden- tification characters AEG,...
  • Page 81 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System for engine speed sender -G28 - 16 - O-ring replace if damaged 17 - Engine speed sender -G28 - resistance between contacts 480...1000 18 - Lambda probe after catalyst -G130 -*, 50 Nm Fitting location: in exhaust pipe downstream of catalytic converter only engines with engine codes AQY, AZH Testing lambda probe and lambda control downstream of catalytic converter...

  • Page 82: Disassembling And Assembling The Air Filter

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Disassembling and assembling the air filter 1 - Air mass meter -G70- with in- take air temperature sender -G42- -G42- resistances Fig. 1 in 24-1 page 10 2 - Gasket ring replace if damaged 3 - Air filter top part 4 - 6 Nm...
  • Page 83 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 1 - Fuel pressure regulator Test fuel pressure regulator and holding pressure Chap. 24-2 2 - Vacuum hose to top part of the intake man- ifold 3 - Cable rail for connector for injection valves -N30 -...-N33- 4 - Bottom part of intake mani-...
  • Page 84 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 1 - Fuel rail with injection valves 2 - Vacuum hose to top part of the intake man- ifold 3 - Cable rail 4 - O-ring replace if damaged 5 - Bottom part of intake mani- fold with variable intake manifold...
  • Page 85 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 1 - 8 Nm 2 - Throttle valve control unit -J338 - 3 - Gasket ring replace if damaged 4 - Pressure relief valve protects intake manifold from damage if excess pressure exists 5 - Vacuum hose from the suction hose...
  • Page 86 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 1 - Retaining clip check for firm seating 2 - Connection return-flow line blue or marked in blue secure with spring strap clip check for firm seating to fuel delivery unit in fuel tank 3 - Connection feed line black with a white marking...

  • Page 87: Testing Components

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 24-2 Testing components Testing cables with test box -V.A.G 1598/ 22- or -V.A.G 1598/31- Special tools, test and measuring equipment and auxiliary items required Test box -V.A.G 1598/22- or - V.A.G 1598/31- Note Use adapter cables from adapter cable set for con- necting the test equipment to the test box.

  • Page 88: Testing Accelerator Pedal Position Sender

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Test conditions • Throttle valve must be in the idling position. • Throttle cable must be correctly set, inspecting l/85 kW Engine, Mechanical Components; Rep. Gr. 20 • On vehicles with an automatic gearbox the selector le- ver must be in position „P“...

  • Page 89: Testing Injected Quantity And Injectors For Leaks

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System the driver input to the engine control unit completely inde- pendently of each other (when accelerator is depressed). Both senders are located in a housing. Test condition • Battery voltage at least 11.5 V. Testing voltage supply and cables to engine control unit –...
  • Page 90 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Test sequence – Remove the fuel rail with injection valves from the in- take manifold (the fuel hoses remain connected) Chapter 24-1. – Detach air guide pipe for air flushing of the injectors –...

  • Page 91: Testing Fuel Pressure Regulator And Holding Pressure

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System If the measurement obtained for one or several injectors is not within the specification: – Replace the faulty injector. Note When testing the injection rate also check the jet forma- tion.
  • Page 92 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System – Connect up the pressure measuring device. – Open shut-off cock of the pressure measuring device. Lever points in direction of flow. – Start engine and run in idle. –...
  • Page 93 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System – Open shut-off cock of pressure measuring device -V.A.G 1318- (lever in direction of flow of fuel). – Start engine and run in idle. – After the pressure has been built up, switch ignition off.
  • Page 94 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Testing components Edition 01.04 24-2 page S00.5128.53.20...

  • Page 95: Check For Proper Operation

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System 24-3 Check for proper opera- tion Testing lambda probe -G39- and lambda control upstream of catalytic converter Special tools, test and measuring equipment and auxiliary items required Handheld multimeter, e.g. -V.A.G 1526 A oder B- Measuring tool set, e.g.

  • Page 96: Testing Lambda Probe Ageing Upstream Of Catalytic Converter -G39

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System – Use handheld multimeter to measure voltage between the contacts 3 and 4 of connector at the wiring loom. For engines with engine codes AZH, AZJ M24-0010 – Use handheld multimeter to measure voltage between the contacts 1 and 5 of connector -2- at the wiring loom.
  • Page 97 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System – Select function 04 „System in basic setting“ and dis- play group 034. For engines with engine code AQY System in basic setting 34 -> – Increase and maintain engine speed at 2200...2800 2800 rpm 355 °C 2.20 s...

  • Page 98: Testing Lambda Probe -G130- And Lambda Control Downstream Of Catalytic Converter

    OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Testing lambda probe -G130- and lamb- da control downstream of catalytic con- verter Only engines with engine identification charac- ters AQY, AZH, AZJ Special tools, test and measuring equipment and auxiliary items required Handheld multimeter, e.g.
  • Page 99 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System – Replace engine control unit Chapter 24-4. 24-3 Edition 01.04 Check for proper operation page S00.5128.53.20...
  • Page 100 OCTAVIA 1997 2,0 l/85 kW Engine, Fuel Injection and Ignition System Check for proper operation Edition 01.04 24-3 page S00.5128.53.20...
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