Skoda Octavia Workshop Manual
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Skoda Octavia Workshop Manual

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Service
Workshop Manual
OCTAVIA
1.9 ltr. / 50 kW (SDI) Engine,
Fuel Injection and Glow Plug System
Service Department. Technical Information
S00.5113.50.20
Edition 08.96

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Summary of Contents for Skoda Octavia

  • Page 1 Service Workshop Manual OCTAVIA 1.9 ltr. / 50 kW (SDI) Engine, Fuel Injection and Glow Plug System Service Department. Technical Information S00.5113.50.20 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 Modifications for vehicles 08.00 ä S00.5113.53.20 Contents ⇒ next page. The Service Manual is intended only for use within the Skoda Organisation; it is not permitted to pass it on to Printed in CR third persons. S00.5113.53.20 © 2000 ŠKODA AUTO a. s.

  • Page 5: Table Of Contents

    OCTAVIA Service Contents Self-diagnosis Page Self-diagnosis ..........................01-1 Features of self-diagnosis ......................01-1 Technical data of self-diagnosis ....................01-1 Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit .. 01-2 Interrogating and erasing fault memory ..................01-5 Fault table ..........................
  • Page 6 Service ------------ 11 ------------ S00.5113.53.20...

  • 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: Connecting Vehicle System Tester V.a.g 1552 And Selecting Engine Electronics Control Unit

    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...
  • Page 9 OCTAVIA Self-Diagnosis ⇒ Notes: ♦ If „Error in data transmission“ is displayed be- cause of an input error, disconnect cable at vehicle system tester, plug it in again and re- peat the steps. K ♦ If one of the following messages appears in...
  • Page 10 OCTAVIA Self-Diagnosis K The control unit identification appears in the dis- 038906013A 1.9l EDC G00SG 1504 → play (example): Coding 00002 WSC 01234 ♦ 038906013A Part No. of control unit ♦ 1.9l Displacement of engine ♦ R4 Type of engine (4-cyl. inline engine) ♦...
  • Page 11 OCTAVIA Self-Diagnosis ♦ 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 01-22. Press → key. K Readout in display: Test of vehicle systems...

  • Page 12: Fault Table

    OCTAVIA Self-Diagnosis If one or several faults are stored: Press the → key. K Fault number appears in the display (example): → Fault number: 00542 Press the → key. Needle lift sender -G80 K Fault source with fault type appear in the dis- →...
  • 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 OCTAVIA Self-Diagnosis Notes: ♦ On vehicles 08.98 ä different fault codes are displayed ⇒ Operating instructions of vehicle system tester with the same or a similar text. In the fault table, select ♦ If components are shown as faulty: the text required on the basis of 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 earth ♦ -G62 faulty ♦ Black exhaust when start- - Test coolant temperature ♦ Cable has short circuit to...
  • Page 16 OCTAVIA Self-Diagnosis Possible sender Short circuit to output temperature ♦ ♦ earth has short circuit to ♦ earth ⇒ Open/short circuit ♦ to positive ♦ Open circuit in short circuit to positive ♦ Several Inspect plug connection ♦ pump stops pump ♦...
  • Page 17 OCTAVIA Self-Diagnosis ♦ Open circuit in wiring or ♦ Hard gearshifts - Test signals from/to auto- short circuit matic gearbox Control difference ♦ Commencement of injec- ♦ Poor performance at high - Test commencement of tion not o.k. revs injection and set ♦...
  • Page 18 OCTAVIA Self-Diagnosis Possible speed signal Implausible signal ♦ Open circuit in wiring be- ♦ CCS not operating - Test road speed signal tween speedometer ♦ AC not operating ⇒ 1.9-ltr./66 kW (TDI) En- sender -G22 and dash ♦ Possible load change jolts...
  • Page 19 OCTAVIA Self-Diagnosis Implausible signal ♦ ♦ ♦ ⇒ ♦ ♦ ♦ ♦ plug ♦ ♦ pump pump ♦ pump ♦ ♦ ♦ ⇒ 00777 sition ♦ ♦ ♦ ♦ ⇒ ♦ ♦ Implausible signal ♦ ♦ ♦ sition Implausible signal ♦...
  • Page 20 OCTAVIA Self-Diagnosis of fault fault Engine unit in- ♦ Invalid control unit coding ♦ Preglow indicator light - Code control unit ⇒ page flashes 01-22 0111 signal for alter- nator Implausible signal ♦ Open circuit in wiring or ♦ Engine preheater not op-...
  • Page 21 OCTAVIA Self-Diagnosis Readout on V.A.G 1552 Fault Possible cause of fault Possible effects fault -J360 Open/short to earth ♦ Open circuit in wiring ♦ Engine preheater not op- - Test cable connections erating ⇒ Current Flow Diagrams, ♦ High heating capacity re- ♦...
  • Page 22 OCTAVIA Self-Diagnosis Short to positive ♦ Short circuit to positive ♦ Glow plug system not op- - Test glow plug relay -J52 erating ⇒ page 01-17, Final con- trol diagnosis Open/short to earth ♦ Open circuit in wiring ♦ Glow system not operat- ♦...
  • Page 23 OCTAVIA Self-Diagnosis Open/short ♦ Open ♦ ♦ ⇒ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ⇒ ♦ ⇒ ♦ ♦ ⇒ ♦ ⇒ ♦ ♦ ♦ Open or short or to ♦ ⇒ Edition 12.00 ------------ ------------ ------------ ------------ S00.5113.53.20...
  • Page 24 OCTAVIA Self-Diagnosis Engine ♦ Attempt at manipulation ♦ Engine starts and cuts - Adapt engine control unit ♦ Attempt at starting with out again immediately to electronic immobiliser non-authorised key ⇒ Electrical System; Re- ♦ Engine control unit not pair Group 96 adapted to immobiliser ♦...
  • Page 25 OCTAVIA Self-Diagnosis on . No message from ♦ ♦ ♦ ⇒ ♦ ♦ No ♦ ⇒ ♦ ♦ ♦ ♦ ⇒ pair ♦ ♦ ⇒ ♦ No ♦ from ⇒ ♦ ♦ Edition 12.00 ------------ ------------ 01-17 ------------ ------------ S00.5113.53.20...
  • Page 26 OCTAVIA Self-Diagnosis No message from ♦ No ♦ ⇒ ♦ ⇒ ♦ No ♦ ⇒ ♦ ⇒ ♦ ♦ ♦ ⇒ ♦ ------------ ------------ ------------ ------------ Edition 12.00 S00.5113.53.20...
  • Page 27 OCTAVIA Self-Diagnosis Final diagnosis final diagnosis With final control diagnosis the following compo- nents are actuated in the order stated: 1. Commencement of injection valve (N108) 2. Exhaust gas recirculation valve (N18) 3. AC compressor control 4. Throttle valve positioner (V60) 5.

  • Page 28: Final Control Diagnosis

    OCTAVIA Self-Diagnosis Test of vehicle systems HELP K Readout in display: Select function XX Press the keys 0 and 3 for the function „Fi- nal control diagnosis“. Test of vehicle systems K Readout in display: 03 - Final control diagnosis Confirm the entry with the key Q.
  • Page 29 OCTAVIA Self-Diagnosis Press the → key. Final control diagnosis K Readout in display: → Throttle valve positioner -V60 Activation of the positioner results in alter- nating changes to the combustion noise (the positioner switches over the throttle valve). Activation of the positioner cannot be heard: Carry out diagnosis of the positioner with the engine off and the ignition switched on.
  • Page 30 OCTAVIA Self-Diagnosis Final control diagnosis K Readout in display: → Glow period warning light -K29 The warning light must flash. If the warning light does not flash: Test glow period warning light 1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System; Repair Group 28 Press →...

  • Page 31: Basic Setting

    OCTAVIA Self-Diagnosis Procedure Connect vehicle system tester V.A.G 1552 and select the engine electronics control unit with the address word „01“. The engine should be idling for this step. (Connecting vehicle system tester and se- lecting engine electronics control unit ⇒ page...
  • Page 32 OCTAVIA Self-Diagnosis If the code to code the c ♦ ⇒ code code ä ä fitted fitted → → Note: ♦ The code entered is activated when the igni- tion is switched on again for the next time. ------------ ------------ Edition 12.00...

  • Page 33: Measured Value Blocks

    OCTAVIA Self-Diagnosis Measured value blocks Reading measured value block Test conditions l Coolant temperature at least 80 °C l Electrical components switched off (radiator fan must not cut in during the test) l Air conditioning switched off l No fault stored in the fault memory Special tools, testers and aids required ♦...
  • Page 34 OCTAVIA Self-Diagnosis Note: Proceed as follows in order to switch into an- other display group: higher Press ↑ key Press key 3 lower Press ↓ key Press key 1 skipping Press key C Press key C Designation Read measured value block 0...
  • Page 35 OCTAVIA Self-Diagnosis Designation Edition 12.00 ------------ ------------ S00.5113.53.20...
  • Page 36 OCTAVIA Self-Diagnosis Designation Read measured value block 7 1 = Fuel temperature Temperatures 2 = No readout 3 = Intake manifold temperature 4 = Coolant temperature Read measured value block 8 1 = Engine speed Injected quan- 2 = Injected quantity request (driver request through accelerator)
  • Page 37 OCTAVIA Self-Diagnosis Designation Read measured value block 12 1 = Ignore readout Glow plug sys- 2 = Glow period (seconds) 3 = Supply voltage from control unit 4 = Coolant temperature Read measured value block 13 1 = Injected quantity variation of cylinder 4 to cylinder 3...
  • Page 38 OCTAVIA Self-Diagnosis engine idling not less ä Read measured value block K Readout in display → 161 127 255 Inducted air mass: ignore Fuel temperature: no specification Intake manifold temperature: no specification Coolant temperature: 80...51 o.k. • > 80: warm up engine...
  • Page 39 OCTAVIA Self-Diagnosis 000 at f road test in 2nd or gear not less 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 40 OCTAVIA Self-Diagnosis 000 at test in 2nd not less 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 41: Engine Idling

    OCTAVIA Self-Diagnosis engine idling not less ä Read measured value block K Readout in display → temperature • piston movement sender • • pump replace pump • load consumers too cold pump replace pump • • pump replace pump •...
  • Page 42 OCTAVIA Self-Diagnosis engine idling not less ä Read measured value block K Readout in display → temperature • piston movement sender • • pump replace pump • load consumers too cold pump replace pump quantity • • pump mixture too...
  • Page 43 OCTAVIA Self-Diagnosis engine idling not less ä Read measured value block K Readout in display → ratio commencement valve • commencement • commencement blocked • valve control pump stops too late test and set commencement • Earlier too cold valve...
  • Page 44 OCTAVIA Self-Diagnosis engine idling not less models ä Read measured value block K Readout in display → ratio commencement valve • commencement o • commencement blocked • valve control pump stops too late test and set commencement • too cold...
  • Page 45 OCTAVIA Self-Diagnosis throttle test in gear not less than 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 46 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 47 OCTAVIA Self-Diagnosis ignition ä Read measured value block → • cable • • cable • ignition ä Read measured value block → • cable • • cable • Edition 12.00 ------------ ------------ S00.5113.53.20...
  • Page 48 OCTAVIA Self-Diagnosis ignition Read measured value block K Readout in display → state state of cruise control pedal monitor able brake pedal monitor available at present Dis la pedal and brake pedal not depressed pedal depressed rake closed pedal depressed...
  • Page 49 OCTAVIA Self-Diagnosis engine idling Read measured value block → able able state of less less Actuation of heating elements Edition 12.00 ------------ ------------ S00.5113.53.20...
  • Page 50 OCTAVIA Self-Diagnosis engine idling engine idling not less Read measured value block K Readout in display → temperature • • state able state pedal position • pedal position sender incorrectly set or • Repair speed • of engine state state...
  • Page 51 OCTAVIA Self-Diagnosis engine idling not less ä ♦ The ♦ ♦ ♦ ♦ ♦ • • • • • > • < • • > • < • • > • < Edition 12.00 ------------ ------------ S00.5113.53.20...
  • Page 52 OCTAVIA Self-Diagnosis engine idling not less models ä ♦ The ♦ ♦ ♦ ♦ ♦ • • • • • • • • • • • • ------------ ------------ Edition 12.00 S00.5113.53.20...
  • Page 53 OCTAVIA Self-Diagnosis engine idling not less than Read measured value block K Readout in display → ratio recirculation valve • readout readout speed • sensors engine on Read measured value block K Readout in display → temperature coolant temperature sender...
  • Page 54 OCTAVIA Self-Diagnosis test in 2nd not less 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 55 OCTAVIA Self-Diagnosis at f throttle road test in 2nd or gear not less than 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 56 OCTAVIA Self-Diagnosis 010 at test in 2nd not less 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 57 OCTAVIA Self-Diagnosis 011 at test in 2nd or gear not less 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: Servicing Diesel Direct Injection System

    OCTAVIA Fuel Preparation/Fuel Injection Servicing diesel direct injection system Safety precautions Pay attention to the following points in order to avoid injuries to persons and/or damage to the fuel injection and glow plug system: ♦ Do not disconnect and connect the cables of...
  • Page 60 OCTAVIA Fuel Preparation/Fuel Injection Survey of fitting locations D - Brake light switch (F) and brake pedal Components A to E are not shown in the ex- switch for CCS/diesel direct injection ploded view. system (F47) A - Relay for diesel direct injection sys- ♦...
  • Page 61 OCTAVIA Fuel Formation/Fuel Injection 2 - Diesel direct injection system control 10 - Plug connection unit (J248) ♦ 3-pin ♦ With altitude sender (F96) ♦ For engine speed sender (G28) 3 - EGR valve (N18) 11 - Plug connection ♦ 10-pin 4 - Mechanical exhaust gas recirculation ♦...

  • Page 62: Removing And Installing Air Filter And Throttle Valve Positioner

    OCTAVIA Fuel Formation/Fuel Injection Removing and installing air filter and throttle valve positioner 1 - O-ring 2 - Throttle valve positioner (V60) for models ä 09.98 Intake manifold flap motor (V157) for models 09.98 ä 3 - 10 Nm 4 - Spring strap clip...

  • Page 63: Removing And Installing Intake Manifold

    OCTAVIA Fuel Preparation/Fuel Injection Removing and installing intake mani- fold Removing Detach the hose pipe from the throttle valve positioner. Slacken the bolt -1- and take off the intake manifold -2-. Take off the shaped rubber element of the cylinder head breather.

  • Page 64: Removing And Installing Injection Pump

    OCTAVIA Fuel Formation/Fuel Injection Removing and installing injection pump Special tools, testers and aids required ♦ Setting straightedge MP 1-312 ♦ Setting device for TDC MP 1-313 ♦ Locking pin 3359 ♦ Counterholder MP 1-216 ♦ Wrench for tensioning toothed belt (e.g. Matra V159, Hazet 2587 or Stahlwille 127-17) ♦...
  • Page 65 OCTAVIA Fuel Formation/Fuel Injection installed Take off orifice plate at inspection opening. Position the crankshaft to TDC of cylinder 1 -arrow-. Screw in setting device for TDC MP 1-313, as shown in the illustration. Position setting device to 90 mm -arrow- (the left notch of the vernier -arrow A- is the reference point).
  • Page 66 OCTAVIA Fuel Formation/Fuel Injection Note: ♦ The valves of cylinder 1 must be closed and the valves of cylinder 4 positioned at overlap. Notes: ♦ Use the locking pin 3359 for counterholding the injection pump gear ⇒ page 23-10, Fig.
  • Page 67 OCTAVIA Fuel Formation/Fuel Injection ♦ On no account slacken the central nut -2- of the injection pump gear otherwise the basic setting of the injection pump will be altered and can no longer be set with workshop equipment. Note: On no account slacken the central nut -2- of the...
  • Page 68 OCTAVIA Fuel Formation/Fuel Injection Align the injection pump gear in the middle of the slots -arrows-. Lock the injection pump gear with the locking pin 3359. Slacken the bolt attaching the camshaft sprocket about 1/2 turn. Note: The adjusting straightedge must not be used as a counterholder when slackening and tightening the camshaft sprocket.
  • Page 69 OCTAVIA Fuel Formation/Fuel Injection Note: K Ensure the retaining claw is correctly located. Note: Use the bolts attaching the injection pump gear only once as these are stretch bolts. Edition 07.99 ------------ ------------ S00.5113.52.20...
  • Page 70 OCTAVIA Fuel Formation/Fuel Injection ⇒ commencement of injection Notes: ♦ The ♦ ♦ ♦ ♦ ♦ ------------ ------------ Edition 07.99 S00.5113.52.20...
  • Page 71 OCTAVIA Fuel Formation/Fuel Injection Test procedure Connect vehicle system tester V.A.G 1552 and select the function „Initiate basic setting“ page 01-20. Check readout in display block 7 (coolant Initiate basic setting → temperature). Specification: less than 73 (equals 85 °C) Do not continue with the test until the coolant temperature is reached.
  • Page 72 OCTAVIA Fuel Formation/Fuel Injection If the commencement of injection is not within the specified range: Switch ignition off. Remove top engine trim panel. Remove top toothed belt guard. Inspect tension of toothed belt. The markings on the tensioning pulley must be positioned opposite.
  • Page 73 OCTAVIA Fuel Formation/Fuel Injection If the commencement of injection is not within the specified range: Correct the setting at the injection pump gear. If the commencement of injection cannot be set within the specified range: Test ejection pressure of pump.
  • Page 74 OCTAVIA Fuel Formation/Fuel Injection Specification: Specification in field A applies to temperatures of 0...50 °C, in field B for temperatures of 50...100 °C. Example: ♦ A temperature of 30 °C equals the specifica- tion 1500...2000 ♦ A temperature of 80 °C equals the specifica- tion 275...375...
  • Page 75 OCTAVIA Fuel Formation/Fuel Injection ⇒ ä Special t required ♦ ♦ ⇒ ⇒ Edition 12.00 ------------ ------------ S00.5113.53.20...
  • Page 76 OCTAVIA Fuel Formation/Fuel Injection For t Test the following cable connections for short circuit to positive and to negative and for open circuit. Rectify any open circuit or short circuit in the wiring. For t Test the following cable connections for short circuit to positive and to negative and for open circuit.
  • Page 77 OCTAVIA Fuel Formation/Fuel Injection recirculation recirculation The test of the exhaust gas recirculation is performed in function 04 - Basic setting. The exhaust gas recirculation valve is pulsed every 10 seconds so as to produce extreme values for exhaust gas recirculation.

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