Skoda OCTAVIA 2004 Workshop Manual
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Skoda OCTAVIA 2004 Workshop Manual

1.9-ltr. / 66 kw (tdi) engine fuel injection and glow plug system
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Service
Workshop Manual
OCTAVIA
1.9-ltr. / 66 kW (TDI) Engine
Fuel Injection and Glow Plug System
Service Department. Technical Information
S00.5111.50.20
Edition 08.96

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Summary of Contents for Skoda OCTAVIA 2004

  • Page 1 Service Workshop Manual OCTAVIA 1.9-ltr. / 66 kW (TDI) Engine Fuel Injection and Glow Plug System Service Department. Technical Information S00.5111.50.20 Edition 08.96...
  • Page 2 The Workshop Manual is intended only for use within the ŠKODA Organisation; it is not permitted to pass it on to third parties. Printed in Czech Republic © 1996 ŠKODA, automobilová a.s.
  • Page 3 Service List of Supplements to Workshop Manual Edition: 01.04 OCTAVIA 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System Replaces List of Supplements - Edition: 09.03 Subject Edition Article Number Supple- ment 08.96 Basic Edition of Workshop Manual S00.5111.50.20 05.97 Supplement to Basic Edition...

  • 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 ..........................01-8 Actuator diagnosis ........................
  • Page 6 Service OCTAVIA Inspecting exhaust gas recirculation system ................23-32 Inspecting exhaust gas recirculation ..................23-32 Inspecting exhaust gas recirculation valve (N18) ..............23-34 Inspecting air mass meter (G70) ....................23-35 Vacuum plan of hose layout plan for the exhaust gas recirculation system ......23-37 Inspecting control units input quantities ..................

  • Page 7: Self-Diagnosis

    OCTAVIA Self-diagnosis Self-diagnosis Features of self-diagnosis The diesel direct injection system control unit is equipped with a fault memory. The fault memory is designed as a permanent memory and as a volatile memory. If faults occur in the monitored sensors or com- ponents, these are stored in the fault memory together with an indication of the fault type.
  • Page 8 OCTAVIA Self-diagnosis Functions available when using vehicle sys- tem tester V.A.G 1552 Please refer to the table below for the require- ments necessary to enable you to select the desired functions. Function Condition Engine not Engine running, idling ignition on 01 Interrogate control unit version 02 Interrogate fault memory...
  • Page 9 OCTAVIA Self-diagnosis Connect vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C. After the vehicle system tester has been con- nected: Depending on the desired function, switch the ignition on or start the engine ⇒ page 01-2, table of „Available functions“.
  • Page 10 OCTAVIA Self-Diagnosis 038906018BQ 1.9 l R4 EDC G00SG 2112 K The control unit identification appears in the dis- → Coding 00002 WSC 01234 play, e.g.: ♦ 038906018BQ Part no. of control unit part ♦ 1.9 l Engine displacement ♦ R4 Engine displacement ver- sion (4 cyl.

  • Page 11: Interrogating And Erasing Fault Memory

    OCTAVIA Self-diagnosis ♦ Storage of non-existent faults in fault memory ♦ Functions not being performed ♦ Reduction in life of automatic gearbox If the code does not match the corresponding version in the vehicle: Check coding of engine control unit ⇒ page 01-23, Coding engine control unit.
  • 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. K Fault source and fault type appear in the dis- Needle lift sender -G80 →...
  • Page 13 OCTAVIA Self-Diagnosis Test of vehicle systems HELP K Readout in display: Select function XX Press the keys 0 and 2 for the function „In- terrogate fault memory“ and confirm the en- try with the key Q. X faults recognized K The number of stored faults appears in the dis- 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 sender ⇒...
  • Page 16 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 00539 17570 Fuel temperature sender -G81 Short circuit to ♦ -G81 faulty ♦ Reduced output - Test fuel temperature earth ♦ Cable has short circuit to sender ⇒...
  • Page 17 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 00545 Engine/gearbox elec- trical connection ♦ Open circuit in wiring or ♦ Hard gearshifts - Test signals from/to auto- short circuit matic gearbox A - Signal for gearshift 00550 17656 Commencement of...
  • Page 18 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 00553 16485 Air mass meter -G70 Implausible signal ♦ Engine was stalled (within - Erase fault memory, con- the last 50 starts) tinue checking vehicle ♦...
  • Page 19 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- ♦ Line interruption between ♦ CCS not operational - Check speed signal speedometer sender -G22 ♦ Air conditioning not opera-  page 23-52 and dash panel insert tional...
  • Page 20 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 ⇒...
  • Page 21 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 01117 17911 Load signal for generator tml. DF Implausible sig- ♦ Line interruption between ♦ Auxiliary heater not opera- - Check wiring Binder: AC generator and diesel tional Current Flow Diagrams, direct injection system...
  • Page 22 Self-Diagnosis OCTAV1A Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 01194 19462 High heat output relay -J360 Line interruption ♦ Line interruption ♦ Engine preheating not op- - Check wiring or short-circuit erational ⇒ Binder: Current Flow Dia- to earth grams, Electrical Fault Finding and Fitting Loca-...
  • Page 23 Self-Diagnosis OCTAV1A Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 01265 17810 Exhaust gas recirculation valve -N18 Short-circuit to ♦ Short-circuit to positive ♦ No exhaust gas positive recirculation 17849 Line interrup- ♦ Line interruption ♦...
  • Page 24 Self-Diagnosis OCTAV1A Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 01269 17659 Commencement of injection valve -N108 Short-circuit to ♦ Short-circuit to positive ♦ Engine jerks when idling positive because commencement of injection is constantly adjusted to “advance”.
  • Page 25 Self-Diagnosis OCTAV1A Readout on 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 26 Self-Diagnosis OCTAV1A Readout on 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 27 Self-Diagnosis OCTAV1A Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 17978 Engine control unit blocked ♦ Manipulation attempt ♦ Engine starts and stops - Adapt engine control unit ♦ Start attempt with an immediately to immobiliser adapted ignition key ⇒...
  • Page 28 Self-Diagnosis OCTAV1A Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault 18058 Data bus drive Missing mes- ♦ Databus lines defective ♦ Poor driveability - Check data bus ⇒ page sage from in- ♦ Incorrect or defective 23-55.3 strument cluster dash panel insert...
  • Page 29 Self-Diagnosis OCTAV1A Readout on V.A.G 1552 Fault number Possible cause of fault Possible effects Rectifying fault For vehicles 08.97 ä 18259 18057 Data bus drive Missing messa- ♦ Databus lines to ABS con- ♦ No vehicle dynamics con- - Check data bus ⇒ page ge from ABS CU trol unit interrupted trol...

  • Page 30: 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 31 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 32 OCTAVIA Self-Diagnosis Press the → key. Final control diagnosis K Readout in display: → Fuel cut-off valve -N109 The engine should stop. If the engine does not stop: Switch off the ignition. Unscrew fuel cut-off valve and clean any metal swarf and dirt. Repeat final control diagnosis;...

  • Page 33: Basic Setting

    OCTAVIA Self-Diagnosis If the warning lamp does not flash: Check glow period warning lamp ⇒ page 28-2. → Press key. K Read-out on display: Actuator diagnosis → Low heat output relay -J359 The relay valve must click. If the relay does not click: Check low heat output relay: ⇒...
  • Page 34 OCTAVIA Self-Diagnosis Special tools, aids and testers required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A, 3B or 3C. Procedure Connect vehicle system tester V.A.G 1552 and select engine electronics control unit (address word 01). The engine must be run- ning in idle.

  • Page 35: Coding Control Unit

    OCTAVIA Self-diagnosis Coding control unit If the code which is displayed does not match the vehicle, or if the control unit has been re- placed, it is then necessary to code the control unit as follows. Special tools, testers and aids required ♦...

  • Page 36: Readiness Code

    Self-Diagnosis OCTAV1A Vehicle system test HELP K Read-out on display Select function XX Enter 06 for the function “end output” and confirm entry with the key Q. 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.
  • Page 37 Self-Diagnosis OCTAV1A Read function 08 “Reading measured value block” and select display group 017. K Read-out on display Reading measured value block → 00000000 00000110 10000000 00000000 Meaning of 8-digit numerical block for readiness code in display field 2 Meaning Ignore Ignore Ignore...

  • Page 38: Generate Readiness Code

    Self-Diagnosis OCTAV1A If the specified values are not reached, gen- erate readiness code ⇒ page 01-26. → Press key. Enter function 06 “End output” and switch off ignition. 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.
  • Page 39 Self-Diagnosis OCTAV1A Work step 2: Erasing fault memory Vehicle system test Enter function 05 “Erasing fault memory” and → confirm entry with key Q. Fault memory is erased Note: Readiness code is erased each time the fault memory is erased. If the ignition is switched off during “Interrogat- ing fault memory”...
  • Page 40 Self-Diagnosis OCTAV1A Work step 7: Switching off ignition Wait at least 5 seconds with ignition OFF. Work step 8: Switching on ignition Wait at least 10 seconds with ignition ON. Work step 9: 2nd test of fuel supply and other systems Start engine.
  • Page 41 Self-Diagnosis OCTAV1A Work step 11: Interrogating fault memory Enter function 02 “Interrogating fault me- mory” and confirm entry with key Q. X fault detected! K The number of stored faults or “No fault de- → tected” appears in the display. If a fault is stored: Rectify fault by referring to the fault table ⇒...

  • Page 42: 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 43 OCTAVIA Self-diagnosis Specified readouts for general vehicle check Display group 000, engine idling (engine warm, coolant temperature not less than +85 °C)  07.97 for models ä Read measured value block K Readout in display → Inducted air mass 70...110 o.k. ♦...
  • Page 44 OCTAVIA Self-diagnosis Display group 000, engine idling (engine warm, coolant temperature not less than +80 °C) 08.97 04.99 for models ä Read measured value block K Readout in display → Inducted air mass tolerance display ♦ Intake ♦ tolerance display ♦...
  • Page 45 OCTAVIA Self-diagnosis Display group 000, engine idling (engine warm, coolant temperature not less than +80 °C) 05.99 for models ä Read measured value block K Readout in display → Inducted air mass 69...110 o.k. ♦ if not within tolerance page 01-50, display group 003 Fuel temperature: 91...201 Intake manifold temperature: 190...80 Coolant temperature: 80...35 o.k.
  • Page 46 OCTAVIA Self-diagnosis Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +85 °C)  07.97 for models ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
  • Page 47 OCTAVIA Self-diagnosis Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80 °C, engine 08.97 04.99 speed 2900...3100 rpm) for models ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦...
  • Page 48 OCTAVIA Self-diagnosis Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80 engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
  • Page 49 OCTAVIA Self-diagnosis Display group ignition Read measured value block K Readout in display → state able state able pedal monitor able pedal Display state of pedal and state of pedal display pedal positions = 1 pedal and brake pedal not depressed pedal depressed closed pedal depressed...
  • Page 50 OCTAVIA Self-diagnosis state state Model fitted with CCS - CCS switched off Model fitted with CCS - CCS switched on 2 5 5 Model without CCS, CCS function is not acti- vated in engine control unit ------------ ------------ Edition 12.00 S00.5111.54.20...
  • Page 51 OCTAVIA Self-diagnosis Display group 016, engine idling Read measured value block 16 → K Readout in display 70.0 % 1 0 0 0 0 0 0 1 13.8 V Supply voltage of control unit: ignore Actuation of heating elements page 01-37, Table 2 Operating state of auxiliary heater page 01-37, Table 1 Generator load: ignore...
  • Page 52 OCTAVIA Self-diagnosis Specified readouts for injection pump Display group 001, engine idling (engine warm, coolant temperature not less than +85 °C)  07.97 for models ä Read measured value block → o.k. ♦ ♦ o.k. ♦ ♦ ♦ load cold o.k. ♦...
  • Page 53 OCTAVIA Self-diagnosis Display group engine idling not less ä Read measured value block → o.k., ♦ o.k. ♦ ♦ ♦ load cold o.k. ♦ ♦ ♦ load cold Display group engine idling not less ä Read measured value block → o.k., ♦...
  • Page 54 OCTAVIA Self-diagnosis Read measured value block → ♦ closed ♦ block ♦ ♦ valve ------------ ------------ Edition 12.00 S00.5111.54.20...
  • Page 55 OCTAVIA Self-diagnosis ä Read measured value block K Readout in display → readout readout piston movement sender at stop ♦ ♦ resistance in cable connection control pump incorrectly set replace piston movement sender at minimum stop ♦ ♦ resistance in cable connection control pump incorrectly set replace...
  • Page 56 OCTAVIA Self-diagnosis engine idling not less than +85 °C) ä Read measured value block → valve ♦ ♦ blocked ♦ valve ♦ cold valve ♦ engine idling not less than +80 °C) ä Read measured value block → valve ♦ ♦...
  • Page 57 OCTAVIA Self-diagnosis ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required). Read measured value block valve ♦...
  • Page 58 OCTAVIA Self-diagnosis test in not less engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
  • Page 59 OCTAVIA Self-diagnosis Display group at full test in gear not less engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
  • Page 60 OCTAVIA Self-diagnosis Specified readouts for engine idling Display group 002, engine idling (engine warm, coolant temperature not less than +85 °C) Read measured value block K Readout in display → 900 rpm 0.0 % 0 1 0 88.4 °C Coolant temperature ♦...
  • Page 61 OCTAVIA Self-diagnosis Display group 013, engine idling (engine warm, coolant temperature not less than +85 °C) 07.97 for models ä ♦ The fuel injection system features a smooth idling control. It is able to detect differences in performance between the individual cylinders (parts tolerances, injector flow, compression, etc.) and to compensate for these by selective metering of the quantity of fuel injected in the idling speed range.
  • Page 62 OCTAVIA Self-diagnosis engine idling (engine not less °C) models ä ♦ The fuel injection system features a smooth idling control. It is able to detect differences in performance between the individual cylinders (parts tolerances, injector flow, compression, etc.) and to compensate for these by selective metering of the quantity of fuel injected in the idling speed range.
  • Page 63 OCTAVIA Self-diagnosis engine idling not less ä Read measured value block K Readout in display → 900 rpm ratio recirculation valve ♦ air mass air mass in display block ♦ ♦ air in intake area inspect intake system leaks recirculation ♦...
  • Page 64 OCTAVIA Self-diagnosis engine idling (engine not less °C) models ä Read measured value block K Readout in display → 900 rpm ratio recirculation valve ♦ air mass air mass in display block ♦ ♦ air in intake area inspect intake system leaks recirculation ♦...
  • Page 65 OCTAVIA Self-diagnosis Read measured value block K Readout in display → temperature coolant temperature sender open circuit in uel temperature is s as a ♦ substitute value temperature intake temperature sender open circuit in a constant as a substitute value ♦...
  • Page 66 OCTAVIA Self-diagnosis Specified readouts for ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required). Read measured value block K Readout in display limit on basis...
  • Page 67 OCTAVIA Self-diagnosis Display group at full (road test in gear not less engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
  • Page 68 OCTAVIA Self-diagnosis test in not less engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
  • Page 69 OCTAVIA Self-diagnosis 07.97 ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required). Read measured value block mbar mbar ♦...
  • Page 70 OCTAVIA Self-diagnosis 010 at test in not less engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
  • Page 71 OCTAVIA Self-diagnosis Display group 010 at full test in gear coolant t not less engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).
  • Page 72 OCTAVIA Self-diagnosis Specified readouts for charge pressure control Display group 011 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +85 °C) 07.97 for models ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦...
  • Page 73 OCTAVIA Self-diagnosis Display group 011 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80 °C, engine 08.97 04.99 speed 2900...3100 rpm) for models ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦...
  • Page 74 OCTAVIA Self-diagnosis 011 at test in not less engine ä Notes: ♦ Accelerate the vehicle at full throttle for the test. ♦ Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person required).

  • Page 75: Rules For Cleanliness

    OCTAVIA Fuel Preparation/Fuel Injection Servicing diesel direct injec- tion system Safety precautions Pay attention to the following precautions in or- der to avoid injuries to persons and/or damage to the fuel injection and glow plug system: ♦ Do not disconnect and connect the cables of the glow plug and fuel injection system - also not of test equipment - unless the igni- tion is switched off.
  • Page 76 OCTAVIA Fuel Formation / Fuel Injection 07.97 Summary of fitting locations ä D - Brake light switch (F) and brake pedal Components A to E are not shown on the sum- mary illustration. switch (F47) ♦ Combined in a housing A - Relay for diesel direct injection sys- ♦...
  • Page 77 OCTAVIA Fuel Formation / Fuel Injection 1 - Mechanical exhaust gas recirculation 11 - Plug connection valve ♦ 2-pin ♦ For needle lift sender (G80) 2 - Injection nozzle with needle lift sender (G80) 12 - Plug connection ♦ 3-pin 3 - Diesel direct injection system control ♦...

  • Page 78: Overview Of Fitting Locations Ä

    OCTAVIA Fuel Formation/Fuel Injection 08.97 07.00 Overview of fitting locations ä Components A to E are not shown in the illus- D - Brake light switch (F) and brake pedal tration. switch (F47) ♦ combined in a housing A - Diesel direct injection system relay ♦...
  • Page 79 OCTAVIA Fuel Formation / Fuel Injection 1 - Intake fitting 11 - Engine speed sender (G28) ♦ With mechanical exhaust gas recir- culation valve 12 - Plug connection ♦ With intake manifold flap ♦ 2-pin ♦ For needle lift sender (G80) 2 - Intake manifold flap changeover valve (N239) 13 - Plug connection...
  • Page 80 OCTAVIA Fuel Formation/Fuel Injection 08.00 Overview of fitting locations ä Components A to E are not shown in the illus- light switch and brake tration. switch ♦ combined in a housing direct injection ♦ in footwell at brake pedal ⇒ page 23-3.2, Fig. 3 ♦...
  • Page 81 OCTAVIA Fuel Formation/Fuel Injection 1 - Mechanical exhaust gas recirculation 14 - Plug connection valve ♦ 2-pin ♦ with intake manifold flap ♦ for needle lift sender (G80) 2 - Intake manifold flap changeover valve 15 - Plug connection (N239) ♦...
  • Page 82 OCTAVIA Fuel Preparation/Fuel Injection Servicing injection pump Note: ♦ Pay attention to safety precautions ⇒ page 23-1 Fuel hoses at the engine must be secured only with spring-strap clips. It is not permitted to use ♦ Pay attention to rules for cleanliness clamp-type or screw-type clips.
  • Page 83 OCTAVIA Fuel Formation/Fuel Injection ♦ for feed line ♦ for cylinder 3 with needle lift sender ♦ 28 Nm ♦ removing and installing, testing ⇒ page 23-16 ♦ tighten screw for return-flow line of ♦ replace cylinder 3 to 10 Nm Fuel ♦...

  • Page 84: Assembly Overview Of Throttle Mechanism

    OCTAVIA Fuel Formation/Injection 1 - Retaining clip 2 - Return line ♦ from injection pump 3 - Feed line ♦ to injection pump 4 - Fuel filter ♦ the direction of flow is marked by ar- rows ♦ for removing loosen clamping screw at bracket ♦...
  • Page 85 OCTAVIA Fuel Formation/Fuel Injection ä racket pedal ♦ testing ⇒ page 23-47 pedal accelerator pedal ä ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C ♦ Hand-held multimeter, e.g. V.A.G 1526A ♦ Test box V.A.G 1598/22 If the sender has been removed: Install cable pulley in position shown.
  • Page 86 OCTAVIA Fuel Formation/Fuel Injection ⇒ 0 1 0 °C 0 1 0 100.0 0 0 0 °C (G79) ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...

  • Page 87: Disassembling And Assembling Air Filter

    OCTAV1A Fuel Formation/Injection Disassembling and assembling air filter 1 - Air mass meter -G70 6 - Filter element ♦ inspecting ⇒ page 23-35. 7 - 10 Nm 2 - Gasket ring 8 - Air filter bottom part 3 - Air filter top part 9 - Air guide 4 - 6 Nm 10 - 6 Nm...

  • Page 88: Removing And Installing Injection Pump

    OCTAV1A Fuel Formation/Injection Removing and installing injection pump Special tools, aids and testers required ♦ Adjusting straightedge MP 1-312 ♦ Adjusting device for TDC MP 1-313 ♦ Rig pin 3359 ♦ Counterholder MP 1-216 ♦ Key for the timing belt tensioner (e.g. Matra V159, Hazet 2587, Stahlwille 127-17) ♦...
  • Page 89 OCTAVIA Fuel Formation / Fuel Injection Remove the top toothed belt guard, the vacuum pump and the cylinder head cover. Remove sound-absorbing pan and air guide pipe between intercooler and turbocharger. Engine installed Take off cover at inspection opening. Position the crankshaft to TDC of cylinder 1 -arrow-.
  • Page 90 OCTAVIA Fuel Formation / Fuel Injection Screw in adjusting device for TDC MP 1-313 as shown in illustration. Set adjusting device to 91.4 mm (the left- hand notch of the vernier -arrow A- is the reference point). Rotate crankshaft until the help marking on the flywheel is aligned with the edge of the adjusting device -arrow B-.
  • Page 91 OCTAVIA Fuel Formation / Fuel Injection Unscrew the nut of the tensioning pulley. Take the toothed belt off the toothed belt sprockets of the camshaft and injection pump. Unplug the connector for the electrical con- nections of the injection pump. Unscrew the securing bolts -1- at the mount- ing bracket.
  • Page 92 OCTAVIA Fuel Formation/Fuel Injection Note: The adjusting straightedge must not be used as a counterholder when slackening and tighten- ing the camshaft sprocket. Counterhold cam- shaft sprocket with special tool MP 1-216. Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 93 OCTAVIA Fuel Formation / Fuel Injection Note: K Ensure the retaining claw is correctly positioned. Tighten the securing nut to 20 Nm. Once again, check the TDC marking at the flywheel. Tighten the new bolts for attaching the injec- tion pump sprocket to 20 Nm. Note: The bolts for attaching the sprocket must only be used once as these are stretch bolts.
  • Page 94 OCTAVIA Fuel Formation / Fuel Injection Connect the injection lines, fuel feed line and electric cables. Fill the injection pump with clean diesel fuel as follows: Screw the connection fitting V.A.G 1318/ 10 into the return flow opening of the in- jection pump.
  • Page 95 OCTAVIA Fuel Formation/Fuel Injection commencement injection Notes: ♦ Commencement of injection must always be checked and set, if necessary, after replac- ing the toothed belt or also after slackening the bolted connections at the injection pump or at the toothed belt sprockets. ♦...
  • Page 96 OCTAVIA Fuel Formation/Fuel Injection ä ⇒ Note: Provided the check reveals that the commence- ment of injection is within the specified range -C-, it is not necessary to carry out any new set- ting. After replacing the injection pump and the engine control unit, the commencement of in- jection should be set to the mean value.
  • Page 97 OCTAVIA Fuel Formation / Fuel Injection Slacken the third bolt attaching the injection pump sprocket and turn the pump shaft slightly: Turning shaft to the left ⇒ commencement of injection retarded Turning shaft to the right ⇒ commencement of injection advanced Note: On no account should you slacken the nuts -2- for the hub otherwise the basic setting of the...
  • Page 98 OCTAVIA Fuel Preparation/Fuel Injection Removing and installing and test- ing injectors Note: Faulty injectors cause the following problems: ♦ Loss of power ♦ Excessive black smoke in exhaust ♦ Intensified blue exhaust when starting from cold ♦ High fuel consumption ♦...
  • Page 99 OCTAVIA Fuel Formation/Injection Preparing an auxiliary tool Saw off an injection line (e.g. spare part line) approx. 5 cm behind the nozzle union nut. Hard solder an M6 bolt to the sawn off line. Thoroughly clean the auxiliary tool, the in- jection nozzle cannot be used if dirty! Tighten the union nut of the auxiliary tool on the jammed nozzle and insert the extractor...
  • Page 100 OCTAVIA Fuel Preparation/Fuel Injection If the fault moves with the injector, replace the relevant injector. If the fault remains at the cylinder, test the compression. If the compression is o.k., replace the rel- evant delivery valve together with seal ⇒ page 23-4, Servicing injection pump. Notes: ♦...

  • Page 101: Wiring And Component Test With Test Box

    OCTAV1A Fuel Formation/Injection Wiring and Component Test with Test Box Note: ♦ For testing use e.g. the handheld multimeter -V.A.G 1526 A or B-, also the voltage tester e.g. -V.A.G 1527 B-. ♦ For connecting measuring equipment (e.g. voltage tester, handheld multimeter etc.) al- ways use the adapter cable set e.g.
  • Page 102 OCTAVIA Fuel Formation/Fuel Injection Notes: ♦ T ♦ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 103 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...

  • Page 104: Replacing Engine Control Unit

    OCTAV1A Fuel Formation/Injection Replacing engine control unit 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- Connect vehicle system tester -V.A.G 1552- and select engine electronics control unit ⇒...
  • Page 105 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 106 OCTAVIA Fuel Formation/Fuel Injection ♦ Warning! Have a second person operate V.A.G 1552. ⇒ → ♦ ♦ ♦ ♦ ------------ 23-22 ------------ Edition 12.00 S00.5111.54.20...
  • Page 107 OCTAVIA Fuel Formation/Fuel Injection If the charge pressure measured is too low, the following faults are possible: ♦ Hose of charge pressure control dropped off, leaking or blocked. ♦ Charge pressure control solenoid valve (N75) blocked. ♦ Mechanism (linkage, shaft) of bypass valve stiff or jammed (bypass valve constantly open).
  • Page 108 OCTAVIA Fuel Formation/Fuel Injection Testing charge pressure control so- lenoid valve (N75) 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) ♦ Test box V.A.G 1598/22 or V.A.G 1598/31 ♦...
  • Page 109 OCTAVIA Fuel Formation/Fuel Injection Replace charge pressure control solenoid valve (N75). Diode test lamp does not flash: End final control diagnosis. Switch ignition off. Connect multimeter for voltage measurement to contact 1 of connector -1- and to earth. Switch ignition on. Specification: approx.
  • Page 110 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 111 OCTAVIA Fuel Formation/Fuel Injection ture sender testers and aids ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C ♦ Hand-held multimeter (e.g. V.A.G 1526 A) ♦ Adapter cable set (e.g. V.A.G 1594 A) ♦ Test box V.A.G 1598/22 or V.A.G 1598/31 Read measured value block, display group 007;...
  • Page 112 OCTAVIA Fuel Formation/Fuel Injection 50...100 ♦ ♦ Test Test Test Test Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 113 OCTAVIA Fuel Formation/Fuel Injection ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 114 OCTAVIA Fuel Formation/Fuel Injection Testing sender and altitude sender testers and aids ♦ ♦ ♦ ♦ ♦ ⇒ → 1013 ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 115 OCTAVIA Fuel Formation/Fuel Injection ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 116 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 117 OCTAVIA Fuel Formation/Fuel Injection control ä control connection at control unit ä acuum element valve return valve ♦ white connection points toward charge pressure control solenoid valve -N75 acuum unit o air control unit ♦ for charge pressure control valve ♦...
  • Page 118 OCTAVIA Fuel Preparation/Fuel Injection Testing start of injection con- trol Testing injection timing control range Special tools, testers and aids required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Procedure Initiate final control diagnosis and actuate the start of injection valve ⇒ page 01-18. Final control diagnosis K Readout in display: →...
  • Page 119 OCTAVIA Fuel Formation/Fuel Injection If the ⇒ ⇒ commencement o injection testers and aids ♦ ♦ ♦ est condition If the ⇒ If the If the Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 120 OCTAVIA Fuel Formation/Fuel Injection ⇒ Test connector at Test Test connector at Test ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 121 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 122 OCTAVIA Fuel Formation/Fuel Injection Testing temperature sender testers and aids ♦ ♦ ♦ ♦ Test procedure ⇒ → Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 123 OCTAVIA Fuel Formation/Fuel Injection Specification: Specification in field A applies to temperature 0...50 °C, in field B to a temperature of 50...100 °C. Example: ♦ A temperature of 30 °C equals a specifica- tion of 1500...2000 ♦ A temperature of 80 °C equals a specifica- tion of 275...375 If the specification is not achieved: Replace injection pump...
  • Page 124 OCTAVIA Fuel Formation/Fuel Injection ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 125 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 126 OCTAVIA Fuel Formation / Fuel Injection Testing exhaust gas recirculation system Testing exhaust gas recirculation Operation of the exhaust gas recirculation sys- tem is tested by measuring the inducted air mass. If exhaust gas is recirculated, the fresh air portion which is detected by the air mass meter is less.
  • Page 127 OCTAVIA Fuel Formation / Fuel Injection ♦ Fault in fault memory Read measured value block → Check the readout in display block 3 (actual 900 rpm 272 mg/H 268 mg/H 54 % air mass). Specification: should agree with specified air mass in display block 2 (tolerance ±...
  • Page 128 OCTAVIA Fuel Formation/Fuel Injection ä ⇒ Note: If a constant value of 550 mg/H is shown in dis- play block 3, test the air mass meter ⇒ page 23-35. ⇒ ⇒ ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 129 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 130 OCTAVIA Fuel Formation/Fuel Injection Testing electromagnetic gas recirculation testers and aids ♦ Hand-held multimeter (e.g. V.A.G 1526 A) ♦ Adapter cable set (e.g. V.A.G 1594 A) ♦ Test box V.A.G 1598/22 or V.A.G 1598/31 Test condition 29 and 34 onnect tester and select engine electronics control unit ⇒...
  • Page 131 OCTAVIA Fuel Formation/Fuel Injection K Test the following cable connections for short circuit to positive and to negative and also for open circuit (connector -1-). 2-pin connector at socket 2, 28 Rectify any open circuit or short circuit in the wiring.
  • Page 132 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 133 OCTAVIA Fuel Formation/Fuel Injection air mass meter The signal from the air mass meter is required by the control unit for calculating the permissi- ble injected quantity and for controlling the ex- haust gas recirculation. The smaller the signal supplied by the air mass meter, the less fuel may be injected.
  • Page 134 OCTAVIA Fuel Formation/ Fuel Injection If the specification is not achieved: Repeat the test and accelerate the vehicle at full throttle. Models ä 07.97 Specification in display block 3: Read measured value block 1850 mbar 1800...2050 mbar (charge pressure) 830 mg/H 1030 mbar 100 % Specification in display block 1:...
  • Page 135 OCTAVIA Fuel Formation/Fuel Injection ä ⇒ socket Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 136 OCTAVIA Fuel Formation/Fuel Injection ä ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 137 OCTAVIA Fuel Formation/Fuel Injection ⇒ ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 138 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 139 OCTAVIA Fuel Formation/Fuel Injection recirculation ä recirculation valve o air return valve acuum acuum element ♦ models 08.97 ä valve ♦ models 08.97 ä ä acuum element valve return valve ♦ white connection points toward charge pressure control solenoid valve -N75 acuum unit o air control...
  • Page 140 OCTAVIA Fuel Formation/Fuel Injection Testing control unit rameters Testing diesel rect injection testers and aids ♦ ♦ ♦ Test conditions ⇒ Test Test Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 141 OCTAVIA Fuel Formation/Fuel Injection ⇒ actuation direct i jection ä Note: It is not easy to hear the clicking of the relay and this is therefore best detected by feeling. ⇒ ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 142 OCTAVIA Fuel Formation/Fuel Injection Electrical contact ⇒ ä Note: It is not easy to hear the clicking of the relay and this is therefore best detected by feeling. ⇒ ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 143 OCTAVIA Fuel Formation/Fuel Injection Test the following cable connections for short circuit to positive and to and also for open Electrical contact open circuit or short circuit in the ⇒ ting binder ignition diesel direct holder position Note: It is not easy to hear the clicking of the relay and this is therefore best detected by feeling.
  • Page 144 OCTAVIA Fuel Formation/Fuel Injection Electrical contact ⇒ ä Electrical contact ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 145 OCTAVIA Fuel Formation/Fuel Injection ä Electrical contact ⇒ ⇒ ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 146 OCTAVIA Fuel Formation/Fuel Injection Test Electrical contact ⇒ ⇒ Test ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 147 OCTAVIA Fuel Formation/Fuel Injection sender testers and aids ♦ ♦ ♦ T Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 148 OCTAVIA Fuel Formation/Fuel Injection Test Ω ⇒ Test ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 149 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 150 OCTAVIA Fuel Formation/Fuel Injection Testing needle sender testers and aids ♦ ♦ ♦ Test Test socket Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 151 OCTAVIA Fuel Formation/Fuel Injection ⇒ 2-pin connector at socket Continued for all models ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 152 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 153 OCTAVIA Fuel Formation/Fuel Injection coolant cable ♦ ♦ cable ♦ ♦ Read measured value cold Read measured value block block → as a as a block Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 154 OCTAVIA Fuel Formation/Fuel Injection 50...100 ♦ ♦ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 155 OCTAVIA Fuel Formation/Fuel Injection ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 156 OCTAVIA Fuel Formation / Fuel Injection Testing brake light switch and brake pedal switch In view of the fact that the fuel injection system operates with an accelerator pedal sender (potentiometer), which could develop a fault, the engine is governed for safety reasons when the brakes are applied.
  • Page 157 OCTAVIA Fuel Formation/Fuel Injection ment sender adjuster testers and aids ♦ ♦ ♦ ♦ T est condition ⇒ → ä → ä ä Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 158 OCTAVIA Fuel Formation/Fuel Injection ⇒ Electrical ment Injection pump connector ä ä ⇒ and cable connector at Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 159 OCTAVIA Fuel Formation/Fuel Injection If the ⇒ 10-pin connector at socket 10-pin connector at socket Continued for all models ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 160 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 161 OCTAVIA Fuel Formation/Fuel Injection accelerator sender testers and aids ♦ ♦ ♦ ♦ T ⇒ → → 0 1 0 → 100.0 0 0 0 ä ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 162 OCTAVIA Fuel Formation/Fuel Injection Ω Ω Ω Ω ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 163 OCTAVIA Fuel Formation/Fuel Injection Test the wiring between test box and connector of sender for open circuit according to the cur- rent flow diagram: 6-pin connector at Test box V.A.G 1598/22, wiring loom, contact socket Rectify any open circuit or short circuit in the wiring.
  • Page 164 OCTAVIA Fuel Formation/Fuel Injection If the specification is achieved: Test voltage supply of accelerator pedal po- sition sender: 6-pin connector at Specification wiring loom, contact 2 + earth approx. 5 V 2 + 3 approx. 5 V 1 + earth approx.
  • Page 165 OCTAVIA Fuel Formation/Fuel Injection K Test the wiring between test box and connector of sender for open circuit according to the cur- rent flow diagram: wiring loom, contact open circuit or short circuit in the no fault is found in the wiring: engine control unit ⇒...
  • Page 166 OCTAVIA Fuel Formation/Fuel Injection ------------ 23-48.4 ------------ Edition 12.00 S00.5111.54.20...
  • Page 167 OCTAVIA Fuel Formation/Fuel Injection additional and to air The AC compressor is switched off by the en- gine control unit in the following situations: ♦ when accelerating from a low speed (recog- nised by change in angle and accelerator pedal position sender and from the vehicle speed signal) ♦...
  • Page 168 OCTAVIA Fuel Formation/Fuel Injection ⇒ contact ⇒ contact ⇒ ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 169 OCTAVIA Fuel Formation/Fuel Injection Read measured value block Specification in display block 3: X X 1 (AC 900 rpm 0.0 % 1 1 1 18.4 °C signal) If the specification is not achieved: Connect test box to the wiring loom to the engine control unit ⇒...
  • Page 170 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 171 OCTAVIA Fuel Formation/Fuel Injection This signal is used to avoid overrevving and load change jolts when the clutch is released, and is required for the cruise control system. ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C ♦...
  • Page 172 OCTAVIA Fuel Formation/Fuel Injection ⇒ contact contact ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 173 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 174 OCTAVIA Fuel Formation/Fuel Injection condition ♦ ♦ ♦ ♦ ♦ ⇒ Warning! Have a second person operate V.A.G 1552. → 0 0 0 000000 ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 175 OCTAVIA Fuel Formation/Fuel Injection Diode test lamp must flash (about 4x for each revolution of wheel). Note: Ensure that the right front wheel does not ro- tate. If the diode test lamp does not flash: Test the following cable connections for short circuit to positive and to negative and also for open circuit.
  • Page 176 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 177 OCTAVIA Fuel Formation/Fuel Injection ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C ♦ Test box V.A.G 1598/22 or V.A.G 1598/31 The engine speed signal is required for the rev counter and for the air conditioning. If an auto- matic gearbox is fitted, it is also required for calculating the shift points.
  • Page 178 OCTAVIA Fuel Formation/Fuel Injection ⇒ ♦ ⇒ ♦ ♦ ♦ ♦ control ♦ condition ⇒ 1552 ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 179 OCTAVIA Fuel Formation/Fuel Injection Readout in display (example): 038906012F 1.9l R4 EDC G000AG 2813 K If G000AG is displayed, cruise control system → is activated. Coding 00001 WSC 01234 038906012F 1.9l R4 EDC 0000AG 2813 K If 000AG is displayed, cruise control system is →...
  • Page 180 OCTAVIA Fuel Formation/Fuel Injection → 000000 → 000000 000011 001011 000111 000001 000000 010011 100011 Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 181 OCTAVIA Fuel Formation/Fuel Injection connector contact Ω Ω Ω Ω ⇒ connector at ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 182 OCTAVIA Fuel Formation/Fuel Injection ä 1552 ♦ ♦ ♦ condition ⇒ readout ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 183 OCTAVIA Fuel Formation/Fuel Injection ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 184 OCTAVIA Fuel Formation / Fuel Injection 08.97 Servicing intake manifold flap ä 1 - Intake manifold 2 - 10 Nm 3 - O-ring ♦ Replace 4 - Intake connection ♦ With exhaust gas recirculation valve and intake manifold flap 5 - 10 Nm 6 - Gasket ♦...
  • Page 185 OCTAVIA Fuel Formation/Fuel Injection ♦ Hand vacuum pump (e.g. V.A.G 1390) ♦ Test box V.A.G 1598/22 or V.A.G 1598/31 ♦ Hand-held multimeter (e.g. V.A.G 1526 A) ♦ Adapter cable set (e.g. V.A.G 1594 A) ♦ Current flow diagram condition l Fuses 29 and 34 o.k. Start engine and run at idling speed for about 5 seconds.
  • Page 186 OCTAVIA Fuel Formation/Fuel Injection ♦ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 187 OCTAVIA Fuel Formation/Fuel Injection ⇒ Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 188 OCTAVIA Fuel Formation/Fuel Injection Edition 12.00 ------------ ------------ S00.5111.54.20...
  • Page 189 OCTAVIA Fuel Formation/Fuel Injection ä 0 recirculation o air Vacuum Vacuum element ♦ models 08.97 ä ♦ models 08.97 ä ä 1 Vacuum element ♦ white connection points toward charge pressure control solenoid valve -N75 Vacuum unit o air control solenoid Pressure unit ♦...
  • Page 191 OCTAVIA Glow Plug System Testing glow plug system Testing operation Special tools, testers and aids required ♦ Hand-held multimeter (e.g. V.A.G 1526) ♦ Current flow diagram Test conditions l Battery voltage at least 11.5 V l Diesel direct injection system control unit (J248) o.k.
  • Page 192 OCTAVIA Glow Plug System If the warning light does not come on: Test glow period warning light ⇒ page 28-2. Testing glow plugs Special tools, testers and aids required ♦ Diode test lamp (e.g. V.A.G 1527 B) ♦ Hinged wrench for glow plugs (e.g. 3220) Test condition l Battery voltage at least 11.5 V Test procedure...
  • Page 193 OCTAVIA Glow Plug System Initiate final control diagnosis and operate glow period warning light ⇒ page 01-18. K Readout in display: Final control diagnosis Glow period warning light -K29 The warning light must flash. If the warning light does not flash: Connect test box to the wiring loom to the engine control unit ⇒...

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