Skoda Octavia 1997 Workshop Manual
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Skoda Octavia 1997 Workshop Manual

1.6 i/75 kw engine, fuel injection and ignition system
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  • Page 3 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System List of Supplements to Workshop Manual Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Edition 06.01 Supple- Edition Subject Article Number ment 06.01 Basic Edition S00.5135.50.20 08.02...
  • Page 4 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System List of Supplements Edition 10.04 S00.5135.52.20...

  • Page 5: Table Of Contents

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Table of Contents 01 – Self-diagnosis Self-diagnosis I ..................01-1 page - Operation ....................01-1 page - Technical data of self-diagnosis ..............01-1 page - Connecting up the vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics ..................

  • Page 6: Operation

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System - Testing lambda probe -G130- and lambda control downstream of catalytic converter ..24-4 page - Test of ageing of lambda probe upstream of catalytic converter -G39- ....... 24-4 page Electronic Engine Power Control (Electronic throttle) ........
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  • Page 13: Self-Diagnosis Ii

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System 01-2 Self-diagnosis II Fault codes 16486 … 16990 Note The fault table is arranged 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 ♦...
  • Page 14 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Readout on -V.A.G 1552- Rectifying fault 16521 Voltage too low Bank 1, probe 2 – 16522 Voltage too high Test lambda probe -G130- and lambda control down- stream of catalytic converter µ Chapter 24-4.
  • Page 15 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Readout on -V.A.G 1552- Rectifying fault 16719 Malfunction – Test resistance of sender (730…1000 Ω). Engine speed sender -G28 – Test wiring and plug connections according to current flow diagram.
  • Page 16 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Readout on -V.A.G 1552- Rectifying fault 16916 Signal too low AC pressure sensor -G65 – Test signal from high pressure sensor for air condition- ing -G65- µ Chapter 24-7.
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  • Page 25: Self-Diagnosis Iii

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System 01-4 Self-diagnosis IV Readiness code Operation The readiness code is an 8-digit numerical code that pro- vides information on the status of the emission-relevant diagnosis. If the diagnosis for a system was successfully performed (e.g.

  • Page 26: Generating Readiness Code

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Meaning of the 8-digit numerical block of the readiness code Checked system Exhaust gas recirculation Lambda probe heater Lambda probes Air conditioning (no diagnosis at present/always 0) Secondary air system...
  • Page 27 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Work step 2: Erasing fault memory – Enter address word „Erase fault memory“ and confirm with Note The readiness code is reset or erased each time the fault memory is erased.
  • Page 28 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System After initiating diagnosis of engine control unit the display in field 4 changes from „Test OFF“ to „Test ON“. – Run engine at idling speed until „Syst. O.K.“ is dis- played in display field 4.
  • Page 29 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Work step 6: Diagnosis of lambda probe after catalyst (ageing test) – for the „indicator group 043“ and confirm en- 0 4 3 try with System in basic setting 43 ->...
  • Page 30 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Note This may take a few mlnutes. – Run engine at high speed until display field 4 indicates specified value „B1-S1 O.K.“. If the display does not occur as described: Interrogate fault memory µ...

  • Page 31: Self-Diagnosis V

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System 01-5 Self-diagnosis V Reading measured value block Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- ♦ Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C- ♦...
  • Page 32 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Analysis: Display group 001, display field 1 - engine speed (idling speed) Display Possible cause of fault Rectifying fault -V.A.G 1552- Test throttle valve control unit µ Chapter less than 640 rpm Throttle valve control unit jams/defective –...
  • Page 33 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 002 Basic functions injection time, air mass meter Engine idling Coolant temperature 80 C Reading measured value < Readout on display → block 2 xxx.x < Display field...
  • Page 34 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 003 Basic functions air mass meter, throttle valve angle Engine idling Coolant temperature 80 C Reading measured value < Readout on display → block 3 x.xx xx.x °...
  • Page 35 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Analysis: Display group 004, display field 2 - supply voltage to the engine control unit Display Possible cause of fault Rectifying fault -V.A.G 1552 - less than 12.5 V AC generator defective, battery heavily –...
  • Page 36 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 005 Engine operating state Engine idling Coolant temperature 80 C Reading measured value < Readout on display → block 5 xxx.x Text km/h < Display field Specification...
  • Page 37 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 010 Ignition angle Engine idling Coolant temperature 80 C Reading measured value < Readout on display → block 10 xx.x ° b. < Display field Specification Analysis Ignition angle 0,0…15.0°...
  • Page 38 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 011 Ignition angle Engine idling Coolant temperature 80 C Reading measured value < Readout on display → block 11 xxx.x xxx.x xx.x ° b. °C °C < Display field...
  • Page 39 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Note on display field 3: What is stated is not the specification as the misfiring rate is checked continuously in the engine control unit. If the fault threshold is exceeded, the fault entries are made and the exhaust warning lamp flashes or lights up.
  • Page 40 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Analysis: Display group 014, 015 and 016 - ignition misfiring Display Possible cause of fault Rectifying fault -V.A.G 1552 - counts up continu- Spark plug defective – ♦ Test spark plugs and spark cables with spark plug connector µ...
  • Page 41 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 023 Knock control Driving Coolant temperature 80 C Reading measured value < Readout on display → block 23 xxxx xxx.x xx.x° xx.x° BTDC BTDC < Display field...
  • Page 42 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 026 Knock sensor voltage signal Engine idling Coolant temperature 80 C Reading measured value < Readout on display → block 26 x.xxx x.xxx x.xxx x.xxx < Display field...

  • Page 43: Reading Measured Value Block - Display Groups 030 To 132

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System 01-6 Self-diagnosis VI Reading measured value block - display groups 030 to 132 Display group 030 Lambda control Engine idling Coolant temperature 80 C Reading measured value < Readout on display block 30 <...
  • Page 44 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 031, lambda control - lambda values upstream of catalytic converter Engine idling Coolant temperature 80 C Reading measured value < Readout on display block 31 x.xxxx x.xxxx <...
  • Page 45 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Analysis: Display group 032, display field 1 and 2 Lambda learned values Display Possible cause of fault Rectifying fault -V.A.G 1552 - low lambda Low learned values when idling at normal –...
  • Page 46 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 033 Lambda control - Lambda probe upstream of catalytic converter Engine idling Coolant temperature 80 C Reading measured value < Readout on display block 33 xx.x x.xx <...
  • Page 47 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 034, diagnosis of lambda probe before catalytic converter (ageing test) Mode basic setting 04 BFQ: Brake and accelerator pedal pressed simultaneously, engine running at fast idling AVU: Brake pedal depressed, engine running at high engine speed System in basic setting 34 <...
  • Page 48 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Voltage of the 4-pin lambda probe in U in mV A: Lambda probe voltage high rich mixture (fuel surplus or air shortage) high CO value B: Lambda probe voltage low...
  • Page 49 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 043, diagnosis of lambda probe after the catalytic converter (ageing test) Mode basic setting 04 BFQ: Brake and accelerator pedal pressed simultaneously, engine running at fast idling...
  • Page 50 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 050 Engine speed increase when AC on Engine idling Coolant temperature 80 C Reading measured value < Readout on display block 50 Text Text < Display field...
  • Page 51 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 054 Engine speed control Driving Coolant temperature 80 C Reading measured value < Readout on display block 54 Text xxx.x xxx.x < Display field Specification Analysis Throttle valve angle (potenti- 0,0…100,0 %...
  • Page 52 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 056 Idling speed stabilisation Engine idling Coolant temperature 80 C Reading measured value < Readout on display block 56 xxxx xxxx xxxxx < Display field Specification Analysis µ...
  • Page 53 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 062 Engine speed control EPC system Ignition on, engine stopped Reading measured value < Readout on display block 62 xx.x xx.x xx.x xx.x < Display field Specification...
  • Page 54 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 066 cruise control system (only on vehicles with cruise control system) Engine idling Reading measured value < Readout on display → block 66 xxxx xxxx km/h km/h <...
  • Page 55 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 070 Diagnosis of activated charcoal filter system (tank vent system) Mode basic setting 04 Engine idling Coolant temperature minimum 60 C System in basic setting 70 < Readout on display xxx.x...
  • Page 56 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Note to display group 074: ♦ The adaptation of the exhaust gas recirculation valve occurs with the ignition on. ♦ The engine control unit is adapted to the exhaust gas recirculation valve by selecting display group 074 under func- ♦...
  • Page 57 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 095 Single-stage intake manifold changeover Engine idling Coolant temperature 80 C Reading measured value < Readout on display block 95 xxxx xx.x xxx.x Text °C < Display field...
  • Page 58 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 120 Traction control system Driving Reading measured value < Readout on display → block 120 xxxx Text < Display field Specification Analysis Status TCS active / TCS n.
  • Page 59 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Reading measured value < Readout on display block 125 Text Text Text Text < Display field Specification Analysis Status airbag Airbag 1 µ 01-6 page 17 Status of the dash panel insert Combi 1 µ...
  • Page 60 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 130 Diagnosis of mapped cooling Engine idling AC switched off Reading measured value < Readout on display block 130 xxx.x xxx.x xx.x Text °C °C < Display field...
  • Page 61 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Display group 132 Diagnosis of mapped cooling Engine idling AC switched off Reading measured value < Readout on display block 132 xxx.x xx.x Text °C °C < Display field...
  • Page 62 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Self-diagnosis VI Edition 10.04 01-6 page S00.5135.52.20...

  • Page 63: 24 - Fuel Formation, Injection

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System 24 – Fuel Formation, Injection 24-1 Fuel Injection System Safety measures Caution! The fuel system is under pressure! Place a cloth around the connecting point before releasing hose connections or when opening the system. Then re- duce the pressure by carefully removing the hose or cap.

  • Page 64: Overview Of Fitting Locations

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Only install clean parts: Remove spare parts from ♦ their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. in tool boxes etc.).
  • Page 65 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System K contacts gold-plated 12 - Camshaft position sensor -G163-* K for engines with engine code BFQ K at rear of cylinder head K inspect µ Chapter 28-1 13 - EGR valve -N18- */**...

  • Page 66: General Notes On The Injection System

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System 28 - 6-pin connector K black K for lambda probe heater -Z19- and lambda probe upstream of catalytic converter -G39- K on underside of vehicle on right 29 - Lambda probe upstream of catalytic converter -G39 -, 50 Nm* K Fitting location: in the exhaust manifold K only coat thread with hot screw paste „G 052 112 A3“;...

  • Page 67: Removing And Installing Parts Of The Injection System

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Removing and installing parts of the injection system Note Components marked with an * are tested by self-diagnosis µ Chap. 01-1. 1 - Air filter K disassembling and assem- bling µ...
  • Page 68 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System K for injection valve -N30...N33- 17 - Gasket ring 18 - Connector K black, 2 pin K for variable intake manifold changeover valve -N156- 19 - Cable rail 20 - Body-bound rivet...

  • Page 69: Disassembling And Assembling Fuel Distributor With Injectors

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System 42 - To secondary air pump 43 - Air mass meter -G70- with intake air temperature sender -G42- * K contacts of sender and of connector gold-plated K resistances for intake air temperature sender -G42- µ 24-1 page 9...

  • Page 70: Disassembling And Assembling Top Part Of Intake Manifold

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Disassembling and assembling top part of intake manifold Note Components marked with an * are tested by self-diagnosis µ Chap. 01-1. ♦ Components marked with ** are tested by final control diagnosis µ Chapter 01-1.

  • Page 71: Disassembling And Assembling The Air Filter

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Disassembling and assembling the air filter Note Components marked with an * are tested by self-diagnosis µ Chap. 01-1. 1 - Air mass meter -G70- with in- take air temperature sender...

  • Page 72: Resistances For The Coolant Temperature Sender -G62

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System – Check resistance values of the intake manifold tem- perature sender -G42- between contacts 2 + 4. Resistances for the coolant temperature sender -G62- The nominal value in field -A- applies for temperature range 0...50 °C, nominal value in field -B- applies for tem-...

  • Page 73: Testing Components

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System 24-2 Testing components Test wiring and components with Test box -V.A.G 1598/31- The test box -V.A.G 1598/31- is designed in such a way that it can be simultaneously connected to the wiring loom of the engine control unit and to the actual engine control unit.

  • Page 74: Inspecting The Injection Rate, Tightness And Jet Formation Of The Injectors

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Inspecting the injection rate, tightness and jet formation of the injectors Special tools, test and measuring equipment and auxiliary items required Hand multimeter (e.g. -V.A.G 1348/2B-) ♦ Digital potentiometer (e.g. -V.A.G 1630-) ♦...
  • Page 75 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System – Hold the injectors in the measuring glasses. – Operate starter (2nd person required). The injectors must spray in a pulsing action in line with firing order. – Switch ignition off and inspect injectors for leaks. No more than 2 drops/min may trickle out.
  • Page 76 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Test fuel pressure regulator and holding pressure The fuel pressure regulator regulates the fuel pressure in line with the intake manifold pressure. Special tools, test and measuring equipment and auxiliary items required Pressure gauge appliancee.g.

  • Page 77: Testing The Intake System For Tightness (Unmetered Air)

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System – Start engine and run in idle. – After the pressure has been built up, switch ignition off. Simultaneously connect the shut-off cock -arrow- to the pressure gauge appliance .

  • Page 78: Testing Brake Vacuum Pump -V192

    Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System – Observe engine speed in display field 1 and readout for lambda control upstream of catalytic converter in display field 3. – Systematically spray parts of the intake system with engine leak search spray.
  • Page 79 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System – Switch off ignition. – Check fuse -3- for the vacuum pump. If fuse is o.k.: – Check voltage supply. The LED does not flash: – Test wiring. S24-0465 Check supply voltage –...
  • Page 80 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Testing components Edition 10.04 24-2 page S00.5135.52.20...
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  • Page 105 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System 28 – Ignition System 28-1 Ignition System General notes on the ignition system The engine control unit is equipped with a self-diagno- ♦ sis system. A minimum voltage of 11.5 V is required for perfect ♦...
  • Page 106 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Removing and installing ignition system 1 - Ignition lead K 4…8 kΩ K with shielded plug and spark- plug K Use extractor -T10112- to unplug spark plug connector. 2 - Ignition transformer -N, N128-...
  • Page 107 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System 15 - 10 Nm K for engines with engine code BFQ 16 - Camshaft position sensor -G163- K for engines with engine code BFQ K check µ 28-1 page 3...
  • Page 108 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Test sequence – Unplug the plug on the camshaft position sensor -G163- -arrow-. For engines with engine code BFQ For engines with engine code AVU Continued for all engines –...
  • Page 109 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System For engines with engine code AVU 3-pin plug -1- on wiring Specification loom, contact 1 + 3 min. 4,5 V If the specified value is not reached: Test wiring µ Current Flow Diagrams, Electrical Fault –...
  • Page 110 Octavia 1997 1.6 l/75 kW Engine, Fuel Injection and Ignition System Ignition System Edition 10.04 28-1 page S00.5135.52.20...

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