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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System List of Supplements to Workshop Manual OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Edition 03.01 Supple- Edition Subject Article Number ment 03.01 Basic Edition S00.5139.50.20...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System List of Supplements Edition 12.03 S00.5139.52.20...
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug 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 ....................
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Testing preheating system ................28-1 page - Check for proper operation ................28-1 page - Checking glow plugs .................. 28-1 page Table of Contents Edition 12.03 S00.5139.52.20...
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System 01 – Self-diagnosis 01-1 Self-diagnosis I Properties of the self-diagnosis The control unit for the diesel direct injection system is equipped with a fault memory. The fault memory is de- signed as a permanent memory.
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Condition Operation Engine not running, Engine idling Normal driving ignition switched on Interrogating control unit version Interrogating fault memo- Actuator diagnosis Basic setting Erasing fault memory Ending output...
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Vehicle system test HELP Fault in communication set-up Vehicle system test HELP K cable does not connect to earth Vehicle system test HELP K cable does not connect to pos. term.
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Only if the engine does not start: – Switch on ignition. – Enter function 02 „Interrogate fault memory“ and con- firm entry with the key. X faults detected! The number of stored faults or „No fault recognised“...
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Note If the ignition is switched off during „Interrogating fault memory“ and „Erasing fault memory“, the fault memory is not erased. – Enter function 06 „End output“ and confirm entry with –...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Readout on display: Actuator diagnosis -> Exhaust gas recirculation valve -N18 The valve must click. Note The clicking of the valve cannot be heard because of the engine noise and can therefore only be checked.
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System If the fan does not run: – Testing radiator fan -V7- and radiator fan control unit -J293- Current Flow Diagrams, Fault Finding Electrics and Fitting Locations. – Press Actuator diagnosis ->...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Self-diagnosis I Edition 12.03 01-1 page S00.5139.52.20...
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System 01-2 Self-diagnosis II Fault table Note The fault table is ordered according to the 5-digit fault code on the left. The SAE code which is displayed on the right next to the fault code (e.g. P0107) can be ignored (at present only valid for USA).
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Readout on -V.A.G 1552- Rectifying fault 16944 Implausible sig- – Test cables to diesel direct injection system control unit - J248- ac- Voltage supply cording to the current flow diagram...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Readout on -V.A.G 1552- Rectifying fault 17668 Implausible sig- – Check unit injector Chap. 23-3 Unit injector solenoid valve cyl. 1 -N240 17669 Regulating limit Unit injector solenoid exceeded valve cyl.
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Readout on -V.A.G 1552- Rectifying fault 17931 Implausible sig- – Test airbag system Body Work; Rep. Gr. 01 Crash signal from air- bag CU 17932 Open circuit or –...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Readout on -V.A.G 1552- Rectifying fault 18026 Short circuit to – Test glow plug relay -J52 - with final control diagnosis Chap. 01-1 Glow plug relay -J52 positive...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Readout on -V.A.G 1552- Rectifying fault 18074 Electrical fault in – Test unit injector Chap. 23-3 Unit injector solenoid the circuit valve cyl. 1 -N240 18075 Unit injector solenoid valve cyl.
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Readout on -V.A.G 1552- Rectifying fault 19560 Short circuit to – Test intake manifold flap changeover valve -N239- with final control Intake manifold flap positive diagnosis Chap. 01-1...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Self-diagnosis II Edition 12.03 01-2 page S00.5139.52.20...
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System 01-3 Self-diagnosis III Readiness code Reading readiness code Operation The readiness codes are two eight-digit numerical codes which indicate the status of the emission-relevant diag- noses. If the diagnosis for a system was successfully performed (e.g.
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Meaning of 8-digit numerical block for readiness code in display field 4 Meaning Ignore Ignore Ignore Ignore Ignore Ignore Ignore Diagnosis of exhaust gas recirculation system – If the specified values are not reached, generate read- iness code 01-3 page 2.
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System – Rectify the faults by referring to the fault table Chapter 01-2. If no fault is stored: – Press Work step 2: Erasing fault memory – Select function „Erase fault memory“...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Readout on display: Reading measured value block -> 1650 rpm 4.1 mg/s 4 0°CA 93.2 °C In this speed range, the exhaust gas recirculation is ac- tive and the control difference is checked. (Condition for generation of readiness code for exhaust gas recircula- tion).
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System If no fault is stored: – Press Reading measured value block -> Readiness code was successfully generated, if no fault is 00000000 00000110 10000000 00000000 stored after repeating the test procedure in the fault mem- ory of the engine control unit and if the following appears in the channel 017.
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Self-diagnosis III Edition 12.03 01-3 page S00.5139.52.20...
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System 01-4 Self-diagnosis IV Reading measured value block 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- Test conditions •...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Display group 002 in idle (engine warm, coolant temperature not below 75 °C) Read measured value block 2 < Readout on display xxx.x x x x xxx.x °C <...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Analysis: Display group 003, display field 2 - inducted air mass (set value) Readout on -V.A.G 1552- Rectifying fault above 350 mg/s – Engine too cold, warm up engine by running at high revs and repeat test.
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Display group 006 in idle (engine warm, coolant temperature not below 75 °C) Read measured value block 6 < Readout on display xx.x km/h < Display field Specification...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Display group 007 with ignition switched on (engine cool and standing) Read measured value block 7 < Readout on display xxx.x xxx.x xxx.x °C °C °C < Display field...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Display group 010 in idle (engine warm, coolant temperature not below 75 °C) Read measured value block 10 < Readout on display xxxx xxxx mbar mbar < Display field...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Analysis: Display group 013, display field 1 to 4 - idle smooth running control The injection system has an idle smoothness regula- tor. It is possible to detect differences in performance between individual cylinders (part tolerances, injector flow, compression etc.) and to compensate for these...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Meaning, if display positions = 1 Additional heating deactivated, because: Coolant temperature sender -G62 - or Intake manifold temperature sender -G72 - defective Ignore Ignore Analysis: Display group 016, display field 3 -...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Analysis: Display group 018, display field 1 through 4 - Display of the conditon of the unit injectors Readout on -V.A.G 1552- Rectifying fault If number instead of zero –...
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Analysis: Display group 022, display field 2 - op- erating state of cruise control system N23-0199 Cruise control Display field 2 Switch B on „ON“ 000011 Switch B on „RES“...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Display group 008 under full load (test drive in 2nd gear coolant temperature not below 75°C) Read measured value block 8 < Readout on display xx.x xx.x xx.x...
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Display group 011 under full load (test drive in 2nd gear coolant temperature not below 75 °C) Read measured value block 11 < Readout on display xxxx xxxx...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Analysis: Display group 125, display field 2, 3 or 4 Readout on -V.A.G 1552- Rectifying fault ABS 0 – Test CAN databus Chap. 23-6. Combi 0 Airbag 0 01-4 Edition 12.03...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Self-diagnosis IV Edition 12.03 01-4 page S00.5139.52.20...
OCTAVIA 1997 1.9 l/74 kW (TDI) Engine, Fuel Injection and Glow Plug System 23-4 Testing exhaust gas recirculation Connection diagram for vacuum hoses 1 - Vacuum unit for throttle valve 2 - Changeover valve for intake manifold flap -N239- desired resistance: 25...45...
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OCTAVIA 1997 1.9 l/74 kW (TDI) Engine, Fuel Injection and Glow Plug System – Connect vehicle system tester -V.A.G 1552-. Start en- gine and select address word 01 „Engine electronics“ Chapter 01-1. – Enter function 04 „basic setting“ and select display group number number 003.
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System 23-5 Engine control unit Testing voltage supply for engine con- trol unit 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-...
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Test box - V.A.G 1598/ Specification 31-, bush 1, 2 + 4, 5 approx. battery voltage 37 + 4, 5 approx. battery voltage If the specified values are not reached: –...
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System – Generate readiness code Chapter 01-3. For all vehicles – Perform a test drive. Note Pay attention to safety precautions during the test drive Chap. 23-1. – Once again interrogate the fault memory of the diesel direct injection system control unit - J248-.
OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Activating and deactivating cruise con- trol system (CCS) 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- Test condition •...
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System 28 – Glow Plug System 28-1 Testing preheating sys- Check for proper operation Special tools, test and measuring equipment and aids required Hand multimeter (e.g. -V.A.G 1526 A-)
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OCTAVIA 1997 1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Checking glow plugs Special tools, test and measuring equipment and aids required Diode test lamp (e.g. -V.A.G 1527 B-) Flexible-head wrench for glow plugs (e.g. -3220-) Test condition •...