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The Service Manual is intended only for use within the koda Organisation; it is not permitted to pass it onto third persons. 1999 KODA AUTO a. s.
Printed in CR
Service
List of Supplements for OCTAVIA Workshop Manual
Edition: 06.00
Subject
Basic Edition Workshop Manual Supplement to Basic Edition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Printed in CR S00.5126.51.20
OCTAVIA
01 Self-diagnosis
Contens
Service
Page
Self-diagnosis .............................................................................................................................. - Features of self-diagnosis ........................................................................................................ - Technical data of self-diagnosis ............................................................................................... - Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit .. - Interrogating and erasing fault memory .................................................................................... - Fault table ................................................................................................................................. - Final control diagnosis .............................................................................................................. - Reading measured value block ................................................................................................ - Reading measured value block: display groups 000 to 010 ..................................................... - Reading measured value block: display groups 011 to 055 .....................................................
01-1 01-1 01-1 01-2 01-4 01-6 01-30 01-32 01-33 01-37
24
Testing lambda control ............................................................................................................... - Operation of lambda control ..................................................................................................... - Testing lambda probe heater .................................................................................................... Testing fuel tank ventilation ....................................................................................................... - Testing solenoid valve 1 for activated charcoal filter ................................................................
Servicing Fuel Injection System ................................................................................................ - Safety precautions .................................................................................................................... - Rules for cleanliness ................................................................................................................ - Technical data .......................................................................................................................... - Survey of fitting locations ......................................................................................................... - General information on fuel injection system ........................................................................... - Removing and installing parts of the fuel injection system ....................................................... - Disassembling and assembling fuel rail and injectors ............................................................. - Disassembling and assembling intake manifold ...................................................................... - Disassembling and assembling air filter ................................................................................... - Testing cables and components with test box V.A.G 1598/31 ................................................. - Replacing engine control unit ................................................................................................... - Testing idling speed .................................................................................................................. - Testing operating states of engine ............................................................................................ - Testing fuel pressure regulator and holding pressure .............................................................. - Testing intake system for leaks (unmetered air) ...................................................................... - Testing injectors ........................................................................................................................ - Testing injected quantity, leaktightness and spray pattern of injectors ..................................... - Testing fuel pump relay -J17 and actuation .............................................................................. - Testing intake manifold pressure sender -G71 ........................................................................ - Testing intake manifold temperature sender -G72 ................................................................... - Testing coolant temperature sender -G62 ................................................................................ - Testing voltage supply for control unit ...................................................................................... - Adapting engine electronics control unit to electronic immobiliser ...........................................
24-1 24-1 24-2 24-2 24-3 24-7 24-8 24-10 24-10 24-11 24-12 24-14 24-15 24-17 24-19 24-22 24-23 24-25 24-27 24-30 24-31 24-34 24-38 24-39 24-41 24-41 24-47
Page
Testing electronic power control (electronic throttle) ............................................................. - Operation of electronic throttle system ..................................................................................... - Meaning of EPC warning lamp (electronic throttle control fault lamp) in dash panel insert ..... - Testing electronic throttle control fault lamp -K132 .................................................................. - Testing throttle valve control unit -J338 .................................................................................... - Conducting adaptation of throttle valve control unit ................................................................. - Testing angle senders for throttle valve drive ........................................................................... - Testing accelerator pedal position sender ................................................................................
24-49 24-49
------------1 ------------
Service
OCTAVIA
24-65 24-65 24-65 24-65 24-67 24-71 24-73 24-75
Testing additional signals .......................................................................................................... - Testing engine speed signal ..................................................................................................... - Testing fuel consumption signal for multifunction display ......................................................... - Testing road speed signal ......................................................................................................... - Testing brake light switch -F and brake pedal switch -F47 ....................................................... - Testing clutch pedal switch -F36- ............................................................................................. - Testing power steering pressure switch -F88- .......................................................................... - Testing databus (CAN bus) ......................................................................................................
28
Ignition System
Testing ignition system .............................................................................................................. - General information on ignition system .................................................................................... - Safety precautions .................................................................................................................... - Setting data of spark plugs ....................................................................................................... - Removing and installing ignition system .................................................................................. - Testing ignition coils with power output stage .......................................................................... - Testing camshaft position sensor -G163 .................................................................................. - Testing knock sensor -G61 ...................................................................................................... - Testing engine speed sender -G28 ..........................................................................................
Page
------------11 ------------
OCTAVIA
01 Self-diagnosis
Contents
Service
Page
Self-diagnosis .............................................................................................................................. - Features of self-diagnosis ........................................................................................................ - Technical data of self-diagnosis ............................................................................................... - Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit .. - Interrogating and erasing fault memory .................................................................................... - Fault table ................................................................................................................................. - Final control diagnosis .............................................................................................................. - Reading measured value block ................................................................................................ - Reading measured value block: display groups 000 to 010 ..................................................... - Reading measured value block: display groups 011 to 055 .....................................................
01-1 01-1 01-1 01-2 01-4 01-6 01-30 01-32 01-33 01-37
24
Testing lambda control ............................................................................................................... - Operation of lambda control ..................................................................................................... - Testing lambda probe heater .................................................................................................... Testing fuel tank ventilation ....................................................................................................... - Testing solenoid valve 1 for activated charcoal filter ................................................................
Servicing Fuel Injection System ................................................................................................ - Safety precautions .................................................................................................................... - Rules for cleanliness ................................................................................................................ - Technical data .......................................................................................................................... - Survey of fitting locations ......................................................................................................... - General information on fuel injection system ........................................................................... - Removing and installing parts of the fuel injection system ....................................................... - Disassembling and assembling fuel rail and injectors ............................................................. - Disassembling and assembling intake manifold ...................................................................... - Disassembling and assembling air filter ................................................................................... - Testing cables and components with test box V.A.G 1598/31 ................................................. - Replacing engine control unit ................................................................................................... - Testing idling speed .................................................................................................................. - Testing operating states of engine ............................................................................................ - Testing fuel pressure regulator and holding pressure .............................................................. - Testing intake system for leaks (unmetered air) ...................................................................... - Testing injectors ........................................................................................................................ - Testing injected quantity, leaktightness and spray pattern of injectors ..................................... - Testing fuel pump relay -J17 and actuation .............................................................................. - Testing intake manifold pressure sender (G71) ....................................................................... - Testing intake manifold temperature sender (G72) .................................................................. - Testing coolant temperature sender (G62) ............................................................................... - Testing voltage supply for control unit ...................................................................................... - Adapting engine electronics control unit to electronic immobiliser ...........................................
24-1 24-1 24-2 24-2 24-3 24-7 24-8 24-10 24-10 24-11 24-12 24-14 24-15 24-17 24-19 24-22 24-23 24-25 24-27 24-30 24-31 24-35 24-38 24-39 24-41 24-41 24-47
Page
Testing electronic power control (electronic throttle) ............................................................. - Operation of electronic throttle system ..................................................................................... - Meaning of EPC warning lamp (electronic throttle control fault lamp) in dash panel insert ..... - Testing electronic throttle control fault lamp -K132 .................................................................. - Testing throttle valve control unit -J338- ................................................................................... - Conducting adaptation of throttle valve control unit ................................................................. - Testing angle senders for throttle valve drive ........................................................................... - Testing accelerator pedal position sender ................................................................................
24-49 24-49
------------1 ------------
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------------11 ------------
Service
S00.5126.51.20
OCTAVIA
Self-Diagnosis
Self-diagnosis
Note: Self-diagnosis monitors only a part of the fuel injection and ignition system.
01
Features of self-diagnosis
The Simos 3PB control unit is equipped with a fault memory. The fault memory is designed as a permanent memory. If faults occur at the monitored sensors or components, these are stored in the fault memory with an indication of the fault type. Faults which occur only occasionally (sporadically), appear in the display with the addition / SP. The cause of a sporadic fault may be, for example, a loose contact or a temporary open circuit in the wiring. If a sporadic fault no longer occurs within 40 engine starts, it is erased from the fault memory. These stored faults can be read with the vehicle system tester V.A.G 1552 or with the fault reader V.A.G 1551 page 01-4. After rectifying the fault or faults, the fault memory must be erased page 01-4. Note: The description which follows relates only to the vehicle system tester V.A.G 1552 using the programme card 5.0 or higher.
01
Self-Diagnosis Function
OCTAVIA
Requirement Ignition on Engine idling yes no
02 03
04 06 08
1) 2)
yes1) yes
05
Ending output
yes yes
no
yes
yes
Only if engine does not start (starter must be operated for at least 6 seconds).
Must be carried out after completing the following operations: Replacing engine control unit, throttle valve control unit or engine, or disconnecting battery.
Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit
Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Test requirements l Battery voltage at least 11 V l Fuses according to up-to-date current flow diagram o.k. l Earth connections at front of clutch housing and at cylinder head o.k.
OCTAVIA
Self-Diagnosis
01
Procedure KConnect vehicle system tester V.A.G 1552 with cable V.A.G 1551/3.
After connecting the vehicle system tester: Either, depending on the function desired, switch on the ignition or start the engine page 01-1, table of Available Functions.
Notes:
If the readout which appears in the display does not correspond to the procedure: Operating instructions of vehicle system tester If Error in data transmission! is displayed because of an incorrect entry, unplug cable at fault reader, plug in again and repeat these steps. Test of vehicle systems Enter address word XX HELP K Readout in display:
Note: Operate the vehicle system by referring to the readout in the display.
Press keys 0 and 1 for the address word Engine electronics and confirm the engine with the key Q.
SIMOS 3PB
K The control unit identification appears in the display (example): 047906033B = Part No. of control unit 1.4 l = Displacement of engine SIMOS 3PB = System designation HS = Manual gearbox SC01 = Software number Press the key.
HELP
01
Self-Diagnosis
OCTAVIA
Switch on ignition.
K Readout in display: Press keys 0 and 2 for the function Interrogate fault memory and confirm the entry with the key Q.
X faults recognized!
K The number of stored faults or No fault recognized! appears in the display. If one or several faults are stored: The stored faults are displayed one after the other.
HELP
K Readout in display: Press keys 0 and 5 for the function Erase fault memory and confirm the entry with the key Q.
Note: If you have switched off the ignition between Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
OCTAVIA
Self-Diagnosis
01
K Readout in display: Press the key. Press keys 0 and 6 for the function End output and confirm the entry with the key Q. Rectify the faults displayed by referring to the fault table page 01-6. After rectifying the faults, it is then necessary to carry out a road test. The following operating conditions must be met during this road test: The coolant temperature must rise to more than 80 C. Once this temperature is reached, the following operating states must be achieved several times: Idling speed Part load Full load Fuel shut-off on overrun. At full throttle, the engine speed must rise to more than 3500 rpm page 24-17. Once again, interrogate the fault memory of the control unit.
If no fault is stored: Test of vehicle systems Select function XX HELP Press the key.
K Readout in display: Press keys 0 and 6 for the function End output and confirm the entry with the key Q.
------------
------------
01 Fault table
Notes:
Self-Diagnosis
OCTAVIA
The fault table is arranged according to the 5-digit fault code shown on the left.
Explanations regarding fault types (e.g. open or short circuit to earth): Operating instructions of vehicle system tester
Readout on V.A.G 1552 16496 Intake air temperature sender -G72 Signal too small Short circuit to earth Sender -G72 faulty Possible cause of fault
The SAE code (e.g. P0107) which is positioned on the right next to the fault code, should be ignored (applies at present only to USA).
If components are shown as faulty: Test cables and plug connections to these components, and also earth cables of the system according to the current flow diagram. Replace component only if no fault is also found in this case. This applies in particular to faults which are shown as sporadic (SP).
Possible effects
Rectifying fault
16497 Intake air temperature sender -G72 Signal too large Short circuit to positive Sender -G72 faulty Emergency mode, control unit operating with substitute temperature
- Read measured value block, display group 004, display block 4 page 01-36. - Test intake air temperature sender page 24-31.
16500 Coolant temperature sender -G62 Implausible signal Coolant temperature sender -G62 supplying implausible signal because of loose contact, or corrosion caused by moisture in connector Signal input in engine control unit faulty (control unit faulty)
- Read measured value block, display group 004, display block 4 page 01-36. - Test intake air temperature sender page 24-31.
Cold start problems at very - Read measured value low temperatures block, display group 004, Poor driving characteristics display block 3 in warming-up phase page 01-36. Increased fuel consump- Test coolant temperature tion sender page 24-35. Increased emission levels - Replace engine control unit page 24-14.
OCTAVIA
Readout on V.A.G 1552 16501 Coolant temperature sender -G62 Signal too small
Self-Diagnosis
01
Rectifying fault
Possible effects
16502 Coolant temperature sender -G62 Signal too large Short circuit to positive Sender -G62 faulty
Cold start problems at very - Read measured value low temperatures block, display group 004, Poor driving characteristics display block 3 in warming-up phase page 01-36. Increased fuel consump- Test coolant temperature tion sender page 24-35. Increased emission levels
16514 Bank 1, probe 1 Electrical fault in circuit Open circuit in wiring or short circuit to earth
Cold start problems at very - Read measured value block, display group 004, low temperatures display block 3 Poor driving characteristics page 01-36. in warming-up phase - Test coolant temperature Increased fuel consumpsender page 24-35. tion Increased emission levels
Lambda closed-loop control switches to open-loop Poor idling Increased emission levels Increased fuel consumption
- Rectify short circuit or open circuit in wiring Current Flow Diagrams, Fault Finding and Fitting Locations binder - Test lambda control page 24-41.
Lambda probe faulty 16515 Bank 1, probe 1 Voltage too small Short circuit of lambda probe signal cable to earth or to screening
- Rectify short circuit or open circuit in wiring Current Flow Diagrams, Fault Finding and Fitting Locations binder - Test lambda control page 24-41. - Read measured value block, display group 030 page 01-38. - Read measured value block, display group 031 page 01-39.
01
Readout on V.A.G 1552 16516 Bank 1, probe 1 Voltage too large
Self-Diagnosis
OCTAVIA
Possible effects
Rectifying fault
- Rectify short circuit or open circuit in wiring Current Flow Diagrams, Fault Finding and Fitting Locations binder - Test lambda control page 24-41.
Lambda probe faulty 16517 Bank 1, probe 1 Signal too slow Lambda probe faulty
Poor idling
16518 Bank 1, probe 1 No activity Lambda probe faulty (dirty) Open circuit in wiring between probe heater and engine control unit Lambda probe heater not operating
Lambda closed-loop control switches to open-loop Poor idling Emission levels not o.k. Increased fuel consumption
- Read measured value block, display group 030 page 01-38. - Read measured value block, display group 031 page 01-39. - Test lambda probe heater page 24-47.
Note on fault codes 16500 - 16502: As soon as one of the faults is recognised, the control unit uses a substitute value from the model map stored in the control unit.
OCTAVIA
Readout on V.A.G 1552 16554 Bank 1, fuel metering system Malfunction
Self-Diagnosis
01
Rectifying fault
Possible effects
Engine does not start Increased emission levels Poor starting characteristics
16555 Bank 1, fuel metering system System too lean Fuel system faulty Lambda closed-loop control switches to open-loop Poor idling Emission levels not o.k.
- Test fuel pressure regulator and holding pressure page 24-19. - Test injectors page 24-23. - Test injected quantity and leaktightness page 24-25. - Test fuel pump: 1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 20; Testing fuel pump - Inspect intake system for leaks page 24-22. - Test exhaust system for leaks: 1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 26; Removing and installing parts of exhaust system - Inspect vacuum lines for leaks.
- Test fuel pressure regulator and holding pressure page 24-19. - Test lambda control page 24-41. - Read measured value block, display group 030 page 01-38. - Read measured value block, display group 031 page 01-39.
01
Readout on V.A.G 1552 16556 Bank 1, fuel metering system System too rich Fuel system faulty
Self-Diagnosis
OCTAVIA
Possible effects
Rectifying fault
- Test fuel pressure regulator and holding pressure page 24-19. - Test lambda control page 24-41. - Read measured value block, display group 030 page 01-38. - Test lambda control page 24-41.
Lambda probe faulty 16705 Engine speed sender -G28 Implausible signal 16706 Engine speed sender -G28 No signal Signal cable has open circuit or short circuit to earth or to positive Engine speed sender -G28 loose
Poor idling
Engine misfires
- Rectify open circuit in wiring or short circuit. Current Flow Diagrams, Fault Finding and Fitting Locations binder - Test engine speed sender -G28 page 28-10. - Replace engine control unit page 24-14.
16711 Knock sensor 1 -G61 Signal too small 16712 Knock sensor 1 -G61 Signal too large
Earth cable has open circuit or short circuit to positive -G28 loose, or faulty Open circuit to screening of -G28 Signal input in engine control unit faulty (control unit faulty)
OCTAVIA
Readout on V.A.G 1552 16719 Engine speed sender -G28 Malfunction
Self-Diagnosis
01
Rectifying fault
Possible effects
- Rectify open circuit in wiring or short circuit. Current Flow Diagrams, Fault Finding and Fitting Locations binder - Test engine speed sender -G28 page 28-10. - Replace engine control unit page 24-14.
Earth cable has open circuit or short circuit to positive -G28 loose, or faulty Open circuit to screening of -G28 Signal input in engine control unit faulty (control unit faulty)
Voltage supply or earth supply for camshaft position sensor -G1631) faulty
-G163 faulty Start problems Signal input in engine control unit faulty (control unit faulty) Open circuit or short circuit to earth or to positive in signal cable between -G163 and engine control unit Timing chain stretched (engines with high mileage) 16726 Camshaft position sensor => sender -G40 Signal too small -G1631) faulty Engine does not rev up to maximum speed Poor performance Start problems Valve timing loud, reduced engine output
- Rectify open circuit in wiring or short circuit according to current flow diagram Current Flow Diagrams, Fault Finding and Fitting Locations binder
- Read measured value block, display group 012; check readouts in display blocks 3 and 4 page 01-37.
- Test camshaft position sensor -G163 page 28-6. - Test cable connection or wiring to -G163 Current Flow Diagrams, Fault Finding and Fitting Locations binder
1)
The camshaft position sensor -G163 is identical with the Hall sender -G40.
01
Readout on V.A.G 1552 16825 Tank vent system Flow faulty
Self-Diagnosis
OCTAVIA
Possible effects
Rectifying fault
16885 Vehicle speed signal Implausible signal Vehicle speed sender faulty Open circuit in wiring or short circuit between vehicle speed sender and speedometer Open circuit in wiring or short circuit between dash panel insert and engine control unit Brief variation between idling speed and specified speed Poor load change characteristics Malfunction in systems which use vehicle speed signal
- Test activated charcoal filter solenoid valve page 01-30, Final control diagnosis 1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 20; Removing and installing activated charcoal filter - Inspect hoses and connection pipes from fuel tank up to throttle valve control unit. 1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 20; Removing and installing fuel tank with attached parts and fuel filter - Rectify open circuit in wiring or short circuit according to CFD Current Flow Diagrams, Fault Finding and Fitting Locations binder
- Read measured value block, display group 005, display block 3 page 01-36. - Rectify open circuit in wiring or short circuit. Current Flow Diagrams, Fault Finding and Fitting Locations binder - Test vehicle speed signal page 24-65.
OCTAVIA
$ ) % 0 $ ) % 0 ( ' $ # & % " ! ' 30 ' 0 1 2 0& 1 & 0
Self-Diagnosis
01
of fault
Idling speed
Idling speed
Smell of fuel
- Test throttle valve control unit page 24-56. - Test injectors page 24-23.
16955
Implausible signal
Open circuit in wiring or short circuit to positive or to earth between brake light switch and engine control unit
- Rectify open circuit in wiring or short circuit according to current flow diagram Current Flow Diagrams, Fault Finding and Fitting Locations binder
No message
Open circuit in datalines to Poor driving characterisABS control unit tics Variations in engine speed when ABS activated Engine control unit faulty Engine does not start
unit
unit
01
------------
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Self-Diagnosis
OCTAVIA
Possible
of fault
Possible
unit
heating
Short to positive
Short circuit to positive in cable from engine control unit to lambda probe
- Test lambda probe heater page 24-47. - Rectify short circuit according to CFD Current Flow Diagrams, Fault Finding and Fitting Locations binder
Output stage in engine control unit faulty (engine control unit faulty) Lambda probe faulty
heating
Insufficient capacity
- Test lambda probe heater page 24-47. - Rectify open circuit according to CFD Current Flow Diagrams, Fault Finding and Fitting Locations binder - Replace engine control unit page 24-14.
Output stage in engine control unit faulty (engine control unit faulty) Lambda probe faulty
------------
OCTAVIA
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Self-Diagnosis
01
of fault
Short circuit to earth in cable from engine control unit to lambda probe Output stage in engine control unit faulty (engine control unit faulty) Lambda probe faulty
- Test lambda probe heater page 24-47. - Replace engine control unit page 24-14.
- Replace lambda probe. 1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 26; Removing and installing parts of exhaust system
Open circuit
- Test lambda probe heater page 24-47. - Rectify open circuit in wiring. Current Flow Diagrams, Fault Finding and Fitting Locations binder - Replace engine control unit page 24-14.
Output stage in engine control unit faulty (engine control unit faulty) Lambda probe faulty
- Replace lambda probe. 1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 26; Removing and installing parts of exhaust system
Implausible value
Reduced output
- Test intake system for leaks (unmetered air) page 24-22. - Erase fault memory page 01-4 and conduct road test.
------------
------------
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Readout on V.A.G 1552 Short to Short to positive -----------to Short Possible positive in in short short in in to of fault
------------
01
Self-Diagnosis
in
to
to
to
Possible
response
response
in
est
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est
OCTAVIA
OCTAVIA
" $ $ # ! ( & % ' $ # $ $ ! 3 1 4 1 1 " # 2 ) ) 0 0
Self-Diagnosis
01
of fault
-G72
Open/short to positive
Open circuit or short circuit to positive in cable connection between intake manifold temperature sender -G72 and engine control unit -G72 faulty Fault in earth supply to -G72
Emergency mode, engine control unit operates with substitute temperature in line with coolant temperature
- Read measured value block, display group 004, display block 4 page 01-36.
- Test intake manifold temperature sender -G72 page 24-31. - Replace engine control unit page 01-36.
17579 Angle
TV
Implausible signal
-G188 faulty or loose contact in plug connection for throttle valve control unit -J338 Signal input in engine control unit faulty (engine control unit faulty) Incorrect connector assignment
Angle
Open circuit or short circuit to earth in signal cable from -G188 to engine control unit
------------
------------
01
------------
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Self-Diagnosis
OCTAVIA
cause of fault
effects
Angle
Engine runs in emergency mode Cold start problems Cold idling problems
Short to positive
Increased emission levels Poor start characteristics Poor driving characteristics Poor throttle response Irregular idling
Short to positive
Short to positive
Short to positive
Short to earth
Increased emission levels Poor start characteristics Poor driving characteristics Poor throttle response Irregular idling
Short to earth
------------
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Readout on V.A.G 1552 Engine Short to Short to 2 Short or to of fault
OCTAVIA
Self-Diagnosis
------------
------------
01
01
Readout on V.A.G 1552 17744 Engine torque monitor Control limit exceeded
Self-Diagnosis
OCTAVIA
Possible effects
Rectifying fault
Leak in intake system Throttle valve control unit -J338 faulty or accelerator pedal position sender -G79 and -G185 faulty; possible cable fault
17746 Bank 1, camshaft position sensor => sender -G1631) Open/short to positive Signal input in engine con- Engine does not rev up to trol unit faulty (engine conmaximum speed trol unit faulty) -G163 faulty Poor performance Loose contact Open circuit or short cir Start problems cuit to positive or to earth between camshaft position sensor -G163 and engine control unit
- Test intake system for leaks page 24-22. - Test throttle valve control unit page 24-56. - Test accelerator pedal position sender page 24-62.
- Test camshaft position sensor -G163 page 28-6. - Rectify open circuit in wiring or short circuit according to CFD Current Flow Diagrams, Fault Finding and Fitting Locations binder
17748 Camshaft position/crankshaft position sensor Incorrect assignment Signal from camshaft sensor not within tolerance
- Test camshaft position sensor -G163 page 28-6. - Read measured value block, display group 012, display block 3 page 01-37.
1)
The camshaft position sensor -G163- is identical with the Hall sender -G40-.
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Possible cause of fault positive positive short short short short
OCTAVIA
Short to positive
Short to positive
Self-Diagnosis
to
to
to
to
Possible effects
Rectifying fault
est
est
est
est
or short to
or short to
or short to
or short to
01
01
% # # & " $ ' % # # & " $ ' ' % # # " $ ! 00 2( 3 # ) # 1& ( )
Self-Diagnosis
OCTAVIA
of fault
unit
unit
Engine
Engine misfires
- Test engine speed sender -G28 page 28-10. - Test sender rotor. 1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 13; Disassembling and assembling cylinder block, crankshaft and flywheel
Short to positive
Short circuit to positive be- Smell of fuel in vehicle tween -N80 and engine control unit -N80 faulty
- Test activated charcoal filter solenoid valve -N80 page 01-30, Final control diagnosis.
Short to earth
Short circuit to earth between -N80 and engine control unit -N80 faulty
- Test activated charcoal filter solenoid valve -N80 page 01-30, Final control diagnosis.
Open circuit
Open circuit in wiring between -N80 and fuse Open circuit in wiring between -N80 and engine control unit Fuse faulty -N80 faulty
- Rectify open circuit in wiring or short circuit according to CFD Current Flow Diagrams, Fault Finding and Fitting Locations binder - Test fuse. - Test activated charcoal filter solenoid valve -N80 page 01-30.
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Idling Idling Readout on V.A.G 1552 Short to Short to -J17 -J17 value value Short Short Possible cause of fault or or to to
OCTAVIA
Self-Diagnosis
Possible effects
01
01
OCTAVIA
cause of fault
effects
Implausible signal
-G187 faulty or loose contact in plug connection for throttle valve control unit -J338
Signal input in engine con- Reduced output trol unit faulty (engine con- Irregular idling trol unit faulty) Incorrect connector assignment
Open circuit or short circuit to earth in signal cable from -G187 to engine control unit
Engine runs in emergency mode Cold start problems Cold idling problems
OCTAVIA
& ' ( & ' $ ! $ $ ! )#) 31& 4% 1!# 0! 0 " # 2 1 1
Self-Diagnosis
01
Possible
of fault
Possible
Malfunction
Fault in voltage or earth supply for throttle valve potentiometer -G69 and throttle valve positioner sender -G127
Open circuit in signal wire for -G69 and -G127 -G69 and -G127 faulty Throttle valve stiff, or dirty
Open circuit in wiring or short circuit to positive Cable has short circuit to earth -G88 faulty
unit
unit
------------
------------
01
------------
" " ! # " ! $ )( 20 3)$ 0% ( $ ( (( & ( $'$ $ 1 0% ' % $ 0
Self-Diagnosis
OCTAVIA
of fault
unit
Throttle valve jamming Throttle valve positioner jamming or has mechanical damage
- Inspect throttle valve for damage or dirt. - Test throttle valve control unit page 24-56.
unit
Mechanical fault
Throttle valve jamming Throttle valve positioner jamming or has mechanical damage
- Inspect throttle valve for damage or dirt. - Test throttle valve control unit page 24-56.
Engine
unit
Attempt at starting with unauthorised key Attempt at manipulation Short circuit in communication line Incorrect coding Fault in immobiliser system Dash panel insert faulty
- Test electronic immobiliser: Electrical System; Repair Group 96; Servicing electronic immobiliser
------------
OCTAVIA
The electronics for controlling the immobiliser is located in the dash panel insert and cannot be replaced separately.
3 3 4 0 % ' 0 # ( 1 1 $ #'# ($0 $ 2 3 )% %0' 0 0 ' &( % " %2 " " ! #' ($ )% % $ ' &# % %
Self-Diagnosis
01
Possible
of fault
Possible
unit
- Inspect connector assignment at throttle valve control unit Current Flow Diagrams, Fault Finding and Fitting Locations binder - Test throttle valve control unit page 24-56. - Replace engine control unit page 24-14.
If an attempt is made to start the engine with a key which is not adapted, a static fault is stored. If the engine is subsequently started with an adapted key, the fault is converted to a sporadic fault.
Possible
of fault
Possible
Voltage
tml.
Alternator faulty
- Test charge state of battery. Electrical System; Repair Group 27; Measuring voltage under load - Test alternator. - Rectify open circuit in wiring according to CFD. Current Flow Diagrams, Fault Finding and Fitting Locations binder - Replace engine control unit page 24-14.
unit
unit
Incorrect coding
------------
------------
01
------------
3 ! 1 2 & ! 0 $ ' # # % ( ! $ & ! ' # ! " ( & ! ' ! " ! $ # % ) " % ! $ % " 6 82! 96& !2! # 4 7# 25" 4 5 2
Self-Diagnosis
OCTAVIA
of fault
Implausible signal
- Test accelerator pedal position sender page 24-62. - Replace engine control unit page 24-14.
unit
------------
OCTAVIA
( & $ 8 6 ( ' 7 $ 4 0 ( ) 1 3 2 & '0 & & $ $ $ # 5 % " # 0 ( ) 1 3 2 $ $ " # # ! # 89# 75' '5& # $ $ & &$ % $# 4#&# 5& 9 # 5
Self-Diagnosis
01
of fault
Faulty
- Test datalines to engine control unit contacts 20, 21 and 41 for open circuit and short circuit page 24-75. - Test ABS control unit. Running Gear; Repair Group 45
Fault in ABS
fault
Short to positive
- Test dash panel insert. Electrical System; Repair Group 90; Dash Panel Insert
fault
Short to earth
Fault lamp comes on and remains on or Fault lamp also does not come on when fault exists
- Test dash panel insert. Electrical System; Repair Group 90; Dash Panel Insert
- Interrogate and erase fault memory page 01-4. - Rectify cause of fault and conduct road test.
------------
------------
01
Self-Diagnosis
OCTAVIA
Note: To repeat final control diagnosis without having switched on the engine in-between, switch off ignition for about 20 seconds.
Procedure Connect vehicle system tester V.A.G 1552 and select engine electronics (address word 01); ignition is switched on for this step page 01-2.
HELP
K Readout in display: Press keys 0 and 3 for the function Final control diagnosis.
Operate fuel pump relay (J17). Final control diagnosis Fuel pump relay -J17 K Readout in display: The fuel pump relay (on relay plate, relay position 4) must continue clicking until the next control element is actuated by pressing the key.
Note: During actuation of the fuel pump relay, it must also be possible to hear the fuel pump operating at intervals.
OCTAVIA
Self-Diagnosis
Final control diagnosis Solenoid valve 1 for activated charcoal filter -N80
HELP
01
If the relay does not click: Test the fuel pump relay page 24-27. Press the key. Actuate solenoid valve 1 for activated charcoal filter (N80). Press the key. K Readout in display: The solenoid valve (in front of coolant reservoir on right) must click until the next control key. element is actuated by pressing the If the solenoid valve does not click: Test solenoid valve 1 for activated charcoal filter page 24-49. K Readout in display: Press the key. K Readout in display: Press keys 0 and 6 for the function End output and confirm the entry with the key Q. Switch off the ignition.
Note:
After ending final control diagnosis, it is necessary to switch off the ignition. If the ignition is not switched off before again starting the engine, the engine is not able to start as the injectors and the ignition transformer are not actuated.
01
Self-Diagnosis
OCTAVIA
HELP
10
K Readout in display: K Readout in display: K Readout in display:
Press keys 0 and 8 for the function Read measured value block and confirm the entry with the key Q.
Enter the desired three-digit display group number and confirm the entry with the key Q.
Note:
skipping
Press key C
Press key C
OCTAVIA
Self-Diagnosis
01
Learned value of mixture formation part load Learned value of mixture formation idling Control value of mixture formation Learned value of idling speed stabilisation Idling speed controller Throttle valve angle Vehicle electrical system voltage Engine speed (idling speed) Ignore readout Coolant temperature
Display block: 1 Coolant temperature Readout in V.A.G 1552 less than 164
Possible cause of fault
Rectifying fault - Conduct road test, if necessary. - Test coolant temperature sender -G62- page 24-34. Clean radiator. Test operation of radiator fan. Test coolant thermostat. Test coolant temperature sender -G62- page 24-34.
Engine too cold Coolant temperature sender or cable connection to engine control unit Radiator dirty Radiator fan not operating Coolant thermostat faulty Coolant temperature sender or cable connection to engine control unit
01
Display block: 3 Engine speed (idling speed) Readout in V.A.G 1552 less than 23 greater than 27
Self-Diagnosis
OCTAVIA
Throttle valve control unit -J338 jamming or faulty Throttle valve control unit -J338 jamming or faulty Large quantity of unmetered air (cannot be compensated for (balanced) by idling speed stabilisation) Possible cause of fault
Display block: 4 Vehicle electrical system voltage Readout in V.A.G 1552 less than 110
- Test throttle valve control unit page 24-56. - Rectify unmetered air. Rectifying fault - Test voltage, charge battery. - Increase revs slightly for a few minutes and switch off ancillaries. - Test voltage supply of engine control unit page 24-38. - Eliminate power drain.
Alternator faulty, battery severely discharged Battery severely discharged shortly after start by high charge current and by ancillaries Contact resistance in power supply or in earth connection for engine control unit Power drain when ignition off Voltage regulator at alternator faulty Overvoltage caused by jump-starting aid or quickcharger Possible cause of fault
Display block: 5 Throttle valve angle Readout in V.A.G 1552 less than 4
- Test voltage, replace regulator, if necessary. - Interrogate fault memory page 01-4. Rectifying fault - Test throttle valve control unit -J338 page 24-56. - Rectify causes of unmetered air.
greater than 12
Display block: 6 Idling speed controller Readout in V.A.G 1552 less than 100 greater than 155
Adaptation of throttle valve control unit -J338 not performed Throttle valve potentiometer in throttle valve control unit -J338 faulty or incorrectly set Throttle valve jamming Possible cause of fault
Throttle valve potentiometer in throttle valve control unit -J338 faulty or incorrectly set Unmetered air between intake manifold and air mass meter (causes fast idling speed; the throttle valve control unit attempts to control fast idling speed to specified idling speed
- Perform adaptation of throttle valve control unit -J338 page 24-56. - Test throttle valve control unit -J338 page 24-56.
Rectifying fault - Test throttle valve control unit -J338 page 24-56. - Perform adaptation of throttle valve control unit -J338 page 24-56.
Throttle valve potentiometer in throttle valve control unit -J338 faulty or incorrectly set
OCTAVIA
Self-Diagnosis
01
Note on display block 4: Meaning of digits in 8-digit numerical block for setting condition for throttle valve adaptation: 1 = condition met 0 = condition not met
x x x x x x x x Condition if display position = 1
1 1 1 1 1 1 1
No fault detected by self-diagnosis Ignore readout AC compressor off (always 1) Idling speed switch closed Lambda control o.k. Throttle valve closed Engine speed less than 2000 rpm 1 Coolant temperature at least 80 C
01
------------
Self-Diagnosis
K Readout in display: X.X % ( ) 0...12 BTDC Ignition angle (actual value) Ignore readout Ignore readout Idling speed page 01-35, display group number 001 K Readout in display: 75...105 C -45...105 C Intake air temperature Coolant temperature Supply voltage of engine control unit Idling speed page 01-35, display group number 001 K Readout in display: 0 km/h Text Vehicle speed Ignore readout Idling speed page 01-35, display group number 001 ------------
OCTAVIA
Operating state (idling speed, enrichment, part load, full load, fuel shut-off on overrun)
OCTAVIA
Self-Diagnosis
01
Coolant temperature
Ignore
If the readout is not within the tolerance and fault 16725 is stored in the fault memory, it is then necessary to check the tension of the timing chain (on engines with high mileage).
01
Self-Diagnosis
OCTAVIA
1 1
------------
Operational readiness of lambda probe Ignore readout X
------------
OCTAVIA
Self-Diagnosis
01
K Readout in display:
------------
------------
01
Meaning of the digits in the 5-digit numerical block for idling speed stabilisation:
x 0 x x x x Meaning
------------
Self-Diagnosis
OCTAVIA
0 %
X.X % ( )
Ignore readout
Operating state (idling, enrichment, part load, full load, fuel shut-off on overrun) page 01-35, display group number 001
Idling speed
K Readout in display:
-10...10 %
00000
Operating states
Table below
Ignore readout
Idling speed
Ignore readout
Always 0
0 Always 0
------------
OCTAVIA
24
The fuel system is pressurized! Place cleaning rags around the connection point before detaching hose connections or opening the test connection (for measuring fuel pressure). Then, release pressure by carefully detaching the hose or the cap. Pay attention to the following points in order to avoid injuries to persons and/or damage to the fuel injection and ignition system: Do not touch or disconnect ignition cables when engine is running or operating at starting speed. Do not disconnect or re-connect cables of the fuel injection and ignition system, also not cables of test equipment, unless the ignition is switched off. To operate the engine at starting speed without it actually starting (e.g. testing compression), unplug connector from the ignition unit and connectors from the injectors. After completing the work, interrogate fault memory and erase. Do not carry out an engine wash unless the ignition is switched off. Do not disconnect and re-connect the battery unless the ignition is switched off otherwise the engine control unit may be damaged.
' # # # 6 D R Q H P ! # D D B &6 H H 7 ! ' ' # 6 ' &I A B 7 ! ' ' % ! # 6' D D & F F 7' 5 ' 6 #& D' B B C #R @" @ B C B7 A ( 5 ! #G #4 ! ! ! ' ( '" 5 " ' " ! # ) ) ! ' # ! ! ! # ! ' E ! 6 & 7' ! 1 ! ' ! ) ! & ! & ! ) ' " ! 9 8 && 1 #'!4 # #" ' ! ! & ! ) ' & 8 ! ! 0 # # ! ! 3 0 # ) ) ) ! 1 ) ) ! ' ( 0 # ) ! ! ') ' ! & ! % ' ' ! # $ ' ! " 4 5 $ $ 4 ' ' " ' 2
Engine code
1)
24
Technical data
10
Pay
1)
A A
AMD
MPa
MPa
MPa (3
OCTAVIA
OCTAVIA
24
connection For lambda probe 1 -G39- and lambda probe heater -Z19 Fitting location Fig. 1
4 Throttle valve control unit With throttle valve drive -G186-, angle sender 1 for throttle valve drive -G187- and angle sender 2 for throttle valve drive -G188sensor In cylinder block below exhaust manifold on left
In plenum chamber
------------
------------
24
OCTAVIA
7 - Engine speed sender -G288 - Ignition unit (ignition transformer with power output stage) -N1529 - Camshaft position sensor -G16310 - PAS pressure switch -F88 Fitting location Fig. 4
11 - Injectors -N30- to -N3312 - Fuel pressure regulator 13 - Activated charcoal filter solenoid valve -N80-
OCTAVIA
24
K Fig. 1
Fitting location of 4-pin plug connection for lambda probe and lambda probe heater
The 4-pin plug connection for lambda probe 1 -G39- and lambda probe heater -Z19- is accessible after unscrewing the protective cover -arrows- at the vehicle floor.
K Fig. 2
1 - Clutch pedal switch -F362 - Brake light switch -F- and brake pedal switch -F473 - Sender for accelerator pedal position -G79- and sender 2 for accelerator pedal position -G185-
------------
------------
24
OCTAVIA
K Fig. 3
K Fig. 4
------------
------------
OCTAVIA
24 on
Servicing ignition system Repair Group 28 Notes: The engine control unit is equipped with selfdiagnosis. First of all, interrogate the fault memory before commencing repairs or fault finding. In addition, also check the vacuum hoses and connections (unmetered air). Components marked with ** can be tested with the final control diagnosis page 01-30. Components marked with * are tested by selfdiagnosis page 01-4, Interrogating fault memory. A voltage of at least 11.5 V is required for proper operation of the electrical components. Always replace collar clamps by screw-type clamps. When conducting certain tests, it is possible that a fault is detected and stored by the control unit. For this reason, always interrogate the fault memory and erase it, if necessary, after completing all tests and repair work page 01-4, Interrogating fault memory. If the engine starts only for a short time and then cuts out again after completing fault finding, repairs or testing of components, this may be caused by the immobiliser inhibiting the engine control unit. In this case, it is necessary to interrogate the fault memory and to adapt the control unit, if necessary page 24-39. Safety precautions page 24-1. Rules for cleanliness page 24-2. Technical data page 24-2. Testing intake system for leaks (unmetered air) page 24-22.
-----------------------
24
------------
'$ 1@ 09 8 "") "0 " $B!& @26&" 3 $ % ( $ ' 1 0 !")" A"$& &&$ 52 4 # 7" !
Fuel Formation/Fuel Injection
OCTAVIA
and
injection
Fitting location: in plenum chamber Attached to mount with clips Testing voltage supply page 24-38
3 Connector, Switch off ignition to unplug or plug in connector Release for unplugging 4 Air Disassembling and assembling page 24-11
2 Connector, Switch off ignition to unplug or plug in connector Release for unplugging
------------
OCTAVIA
7 - Inlet hose 8 - 8 Nm 9 - Inlet connection At throttle valve control unit 10 - Inlet connection
Fuel Formation/Fuel Injection 14 - 4-pin plug connection For lambda probe and lambda probe heater On right of vehicle floor next to lambda probe below a cover 15 - Intake manifold Disassembling and assembling page 24-10 16 - Connection hose From pressure regulator to inlet connection -item 2017 - Fuel return-flow hose Secure at fuel rail with spring strap clamp Blue, or blue marking 18 - Fuel feed hose Secure at fuel rail with spring strap clamp Black, or white marking 19 - To crankcase ventilation 20 - To fuel pressure regulator -item 1621 - Intake hose 22 - Collar clamp
24
11 - Connector For coolant temperature sender -G6212 - Coolant temperature sender -G62-* With coolant temperature gauge sender -G2 Identification: yellow ring Before removing, equalise pressure in cooling system if necessary Testing page 24-35 Resistances page 24-12, Fig. 1 13 - Lambda probe -G39-*, 55 Nm Fitting location: in front exhaust pipe Coat thread with G 052 112 A3 paste; paste must not get into the slot of the probe body Testing lambda probe and lambda control page 24-41
24
& @ ( P 1 6 ( & ( S P 8 2 6 & 0@ ( I) #8 H 1 ! F E G CA & Q R' 5' ' 8 6 B ( & 0 9 ( 7 & % 9'5 &' @ ( 6 7 A 3 8 2 1 ) & % $ D ! # "" 5' 4 "5' 5 ( ( 0 '
OCTAVIA
2 Replace if damaged Injectors Testing page 24-23 Resistance 14...17 clamp 4 7 Ensure tight and correctly installed Fuel pressure Testing pressure regulator and holding pressure page 24-19 9 Collector strip For injectors, throttle valve control unit and intake manifold pressure/temperature sender
and
valve control unit Testing page 24-56 With throttle valve drive -G186-, angle sender 1 for throttle valve drive -G187- and angle sender 2 for throttle valve drive -G188 Replace
Replace
OCTAVIA
7
E $ 0 1 G $ $ ( $ ( ' E E ( E ( F F E 0 $ 6 7 A @ 6 4 4 5 4 7 A @ 6 4 4 5 8 2 8 3 9 $ ) 0$ 9 )3# ( 0 1 03 9 % 1B 1 ) (!3 $C! " $ D $ $ # " ! 1 ' 0 % 0 % && $
Fuel Formation/Fuel Injection 0 T
24
To
Activated charcoal filter system Engine Mechanical Components; Repair Group 20; Removing and installing parts of activated charcoal filter system 2
and
air
Inlet connection
2 T
6 7
air connection
connection
0 I
24
OCTAVIA
K Fig. 1
The range A indicates the resistances for the temperature range 0...50 C, range B the resistances for the temperature range 50...100 C. Examples of how to read chart:
K Fig. 2
The range A indicates the resistances for the temperature range 0...50 C, range B the resistances for the temperature range 50...100 C. Examples of how to read chart:
Notes:
Test box V.A.G 1598/31 is designed in such a way that it can be connected at the same time to the wiring loom to the engine control unit and to the engine control unit itself.
This offers the advantage that the electronic engine control remains fully operational even when the test box is connected (e.g. for measuring signals when engine running).
Edition 07.99 S00.5126.50.20
OCTAVIA
Fuel Formation/Fuel Injection Refer to the particular test procedure to determine whether the control unit is connected to the test box or not.
24
Always use adapter cable set V.A.G 1594 A for connecting test equipment (e.g. voltage tester V.A.G 1527 B, hand-held multimeter V.A.G 1526 A etc.). The contact numbers of the control unit connector and the socket numbers of the test box are identical. Warning!
Switch on the relevant measuring range and pay attention to the test conditions before connecting the test cables in order to avoid damaging the electronic components. Switch ignition off.
Unscrew windscreen wiper arms and remove the cover of the plenum chamber. Body Fitting Work; Repair Group 66; Trim Panels KRelease the connector catches and unplug the control unit connector. Connect test box V.A.G 1598/31 to the connector of the wiring loom. The earth clip -arrow- should be connected to the test box and to the battery. Refer to the particular test procedure to determine whether the control unit is connected to the test box or not. Carry out the test as described in the particular repair procedure.
Note:
After re-connecting the engine control unit, it is then necessary to adapt the engine control unit to the throttle valve control unit page 24-56.
24
OCTAVIA
Unscrew the windscreen wiper arms and remove the cover of the plenum chamber. Body Fitting Work; Repair Group 66; Trim Panels
Note: When removing the cover, detach the hose for the spray nozzles.
KUse a screwdriver to press the catch of the fixture to the side and pull the engine control unit forward. Release the connector catches and unplug the control unit connectors.
Important note: After installing the engine control unit, it is necessary to carry out the following steps:
Adaptation of throttle valve control unit (J338) page 24-56. Adaptation of engine control unit to immobiliser control unit page 24-39.
OCTAVIA
24
Notes:
Idling speed cannot be adjusted. Idling speed is tested during basic setting of the engine. During the basic setting, the activated charcoal filter solenoid valve (ACF valve -N80) is closed and the AC compressor is switched off. Test procedure Connect vehicle system tester V.A.G 1552 and select engine electronics (address word 01); engine idling for this step page 01-2. Interrogate fault memory page 01-4. There must not be any fault stored; if necessary, rectify faults, erase fault memory, switch off engine and start again, conduct a road test and once again interrogate fault memory as a check. Continue running engine at idling speed.
Warning! The radiator fan must not cut Installation is carried out in the reverse order; pay attention to the following points:
Test of vehicle systems Select function XX HELP K Readout in display: Press keys 0 and 4 for the function Basic setting and confirm the entry with the key Q.
24
------------
Fuel Formation/Fuel Injection
OCTAVIA
Enter 056 for Display group number 056 and confirm the entry with the key Q.
2.5 %
00000
K Readout in display: -
Check whether the engine speed in display block 1 (actual engine speed) is within the permissible tolerance range of display block 2 (specified engine speed).
Notes:
The engine speed in display block 1 (actual engine speed) is the speed at which the engine is running at that moment.
The speed in display block 2 (specified engine speed) is a theoretical speed computed by the engine control unit. In the idling speed range, the engine control unit always attempts to adapt the actual engine speed to the specified engine speed.
What this means is that in the idling speed range the actual engine speed must always approximately equal the specified engine speed.
Display blocks 3 and 4 are for information purposes only but are not relevant for checking the idling speed.
HELP
page
If idling speed is too high or too low and no fault is stored in the fault memory, carry out the tests below marked with a dot: l Unmetered air in intake system, testing page 24-22. l Throttle valve control unit, testing 24-56.
page
l Activated charcoal filter solenoid valve constantly open, testing page 24-49.
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OCTAVIA
24
HELP
K Readout in display (function selection): Press keys 0 and 8 for the function Read measured value block and confirm the entry with the key Q.
K Readout in display: Press keys 0, 0 and 1 for Display group number 001 and confirm the entry with the key Q.
1011111
K Readout in display: (1...4 = display blocks) Check in display block 2 whether the coolant temperature is more than 80 C. Switch to display group 005 as follows: Press the key C. Press keys 0, 0 and 5 for Display group number 005 and confirm the entry with the key Q.
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24
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Fuel Formation/Fuel Injection
OCTAVIA
Idling
Part load: -
Deceleration mode: -
Increase engine speed to more than 3000 rpm. Close throttle valve suddenly.
Full load: -
Note:
It may be necessary to carry out a road test in order to obtain the full load readout.
Attach fault reader on the rear seat and operate it from this point.
Press the key.
Press keys 0 and 6 for the function End output and confirm the entry with the key Q.
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Fuel Formation/Fuel Injection If the specifications are not achieved: Interrogate the fault memory, rectify any faults present and then erase the fault memory page 01-4, Interrogating and erasing fault memory. Test the accelerator pedal position sender page 24-62.
24
fuel
regulator and
The fuel pressure regulator regulates the fuel pressure in line with the intake manifold pressure. t t and
l Delivery of fuel pump o.k.; testing: 1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 20; Removing and installing parts of fuel supply system; Testing fuel pump
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24
K-
Specification: 2.7...3.3 bar (0.27...0.33 MPa). If the specification is not achieved: Switch ignition off.
Check non-return valve of fuel pump and fuel line. 1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 20; Removing and installing parts of fuel supply system; Testing fuel pump. If the specification is achieved: -
B 9 " # " " " A " ' # " ! " # # # " " " ! ! # ) " " # !" ! ! @ # # " # " " " ' ! 0 8 ( 3 1 2 1 # 6 $ ) # " " " & ! 9 " #%) 7 " # # 6 % # #) " ' " ) " " " # " ! # $ ' # 4 " 0 ( 3 1 2 1 4# % $% #) ) # # $ "5 8% ) " " # ! ! & ' ) " ) ")5 7 ' % % ) !% # !
Before disconnecting the pressure measuring device, release pressure by carefully detaching the hose from the feed line in stages. Hold a vessel and cloth below the connection for collecting the fuel which flows out. Note: -----------------------
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KK-
24
24
OCTAVIA
Notes:
As a result of the vacuum in the intake system, the leak detection spray is inducted together with the unmetered air. The leak detection spray reduces the ignition performance of the mixture. This results in a drop in engine speed and an enlargement of the throttle valve angle. It is essential to observe the safety precautions stated on the can. Connect vehicle system tester V.A.G 1552 and select engine electronics (address word 01); engine idling for this step page 01-2.
HELP
K Readout in display: Enter 08 for the function Read measured value block and confirm the entry with the key Q.
K Readout in display: Enter 011 for Display group number and confirm the entry with the key Q.
9.0 BTDC
K Readout in display: (1...4 = display blocks) Check the readout in display block 1 (engine speed) and note. Systematically spray parts of the intake system with engine leak detection spray.
If the engine speed drops or if the readout increases beyond the earlier limits: Inspect sprayed point of intake system for leaks and rectify any leak. Press key. Press keys 0 and 6 for the function End output and confirm the entry with the key Q.
OCTAVIA
24
Testing injectors
Testing actuation Special tools, testers and aids required Test box V.A.G 1598/31 Hand-held multimeter (e.g. V.A.G 1526 A) Diode test lamp (e.g. V.A.G 1527 B) Adapter cable set (e.g. V.A.G 1594 A) Current flow diagram Test conditions K l Fuse 32 must be in proper order. l Earth connections between engine (at clutch housing) and body (below battery) in proper order. l Battery voltage at least 11 V. l Engine speed sender must be in proper order; testing page 28-10. l Fuel pump relay must be in proper order. Test procedure KRemove the engine trim panel. Unplug the connectors -1- from the injectors -2-. Use adapter cables from V.A.G 1594 A to connect the diode test lamp to the contacts of the connector of cylinder 1.
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24
OCTAVIA
Operate the starter. The LED must flicker. Repeat the test at the connectors of the injectors of cylinders 2...4.
If the LED does not flicker: KSwitch off ignition. Connect test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12.
K-
Test cable connection between contact 1 and fuse for injectors for open circuit. Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder Rectify any open circuit in the wiring.
Test the cables between test box and the connectors of the injectors for open circuit according to the current flow diagram. Connector cyl. 1, contact 2+socket 88 Connector cyl. 2, contact 2+socket 87 Connector cyl. 3, contact 2+socket 85 Connector cyl. 4, contact 2+socket 86 Cable resistance: max. 1.5 In addition, test the cables for short circuit to each other to positive. Specification: Connect voltage tester V.A.G 1527 B as follows: Plug connection Contact 1 Measure to Engine earth Briefly operate the starter (the engine may also start when this is done). The LED must come on. Test actuation of the injectors.
Edition 07.99 S00.5126.50.20
OCTAVIA
24
Testing resistances of injectors KTest the resistance of the injectors between the contacts. Specification: 14...20
K-
Inspecting for leaks Initiate final control diagnosis page 01-30 and actuate the fuel pump relay -J17-. Check the injectors for leaks (visual inspection). When the fuel pump is running, no more than 1...2 drips a minute must flow out of each injector. If the fuel loss is greater, switch off fuel pump (end final control diagnosis) and replace the faulty injector page 24-10.
24
OCTAVIA
Testing injected quantity Hold the injector to be tested in a measuring glass of the injected quantity tester V.A.G 1602. Connect one contact of the injector with the test cable and a crocodile clamp from V.A.G 1594 A to engine earth. Connect the second contact of the injector with the remote control V.A.G 1348/3A, adapter cable V.A.G 1348/3-2 and auxiliary cable to positive. Initiate final control diagnosis page 01-30 and actuate the fuel pump relay -J17-. The fuel pump must run. Operate remote control V.A.G. 1348/3A for 30 seconds. Repeat the measurement at all the injectors. After all four injectors have been actuated, place the measuring glasses on a flat surface. Specification for each injector: 145 12 ml If the measurement obtained for one or several injectors is not within the tolerance, switch off fuel pump (end final control diagnosis) and replace the faulty injector page 24-10.
K-
Note: When testing the injected quantity, also inspect the spray pattern. The ejected spray must be identical at all the injectors.
Install the injectors and the fuel rail page 24-10.
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OCTAVIA
24
Note:
K The fuel pump relay is located on the micro electrical centre in the driver footwell on left, plug position 4. Test requirement: l Battery voltage at least 11 V Operational test of fuel pump relay Remove the bottom part of the dash panel on the left: Body Fitting Work; Repair Group 70; Dash Panel; Removing and installing dash panel Connect vehicle system tester V.A.G 1552 and select engine electronics (address word 01); ignition is switched on for this step page 01-2. Initiate final control diagnosis page 01-30 and actuate the fuel pump relay -J17-.
If the fuel pump relay does not operate: Test actuation of fuel pump relay.
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The fuel pump relay must operate and the fuel pump must run.
24
OCTAVIA
If the fuel pump does not run: Test voltage supply for fuel pump and components (through fuel pump relay) page 24-27.
Testing actuation of fuel pump relay KSwitch off the ignition. Connect test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12. Use an adapter cable from V.A.G 1594 A to connect socket 80 and socket 2 of the test box. Switch on the ignition.
The fuel pump relay must operate. If the relay now operates, but not during final control diagnosis: Replace the engine control unit page 24-14.
If the relay does not operate: KSwitch off the ignition. Remove the fuel pump relay. Connect the multimeter for voltage measurement to contact 19 of relay base and to earth. Switch on the ignition. Specification: approx. battery voltage If the specification is not achieved: - Test the cable connections. Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder If the specification is achieved: Switch off the ignition.
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OCTAVIA
24
K-
Test the following cable connection for open circuit and for short circuit to earth and to positive: Micro electrical centre in driver footwell on left, plug position 4 Contact 16 Test box V.A.G 1598/31 Socket
80
Rectify any open circuit or short circuit in the wiring. If the cable connections are in proper order, replace the fuel pump relay -J17.
Testing voltage supply for fuel pump and components KRemove fuses 28, 32, 34 and 43 in the fuse holder. Initiate final control diagnosis page 01-30, and actuate the fuel pump relay -J17-. Connect the multimeter for voltage measurement to earth and to one of the contacts of the following fuses in the fuse holder. Fuse S28 S32 S34 S43 Specification at one of the contacts approx. battery voltage approx. battery voltage approx. battery voltage approx. battery voltage
If the specifications are not achieved: Repeat the test at the other contact of the fuse base.
If the specifications are again not achieved: - Test the cable connections. Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder If the cable connections are o.k., replace fuel pump relay -J17.
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24
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Fuel Formation/Fuel Injection
OCTAVIA
K-
Unplug connector -1- from intake manifold pressure sender (G71) and intake manifold temperature sender (G72) -2-. Switch ignition on.
Specification approx. 5 V
approx. 5 V
Replace intake manifold pressure sender (G71) together with intake manifold temperature sender (G72) page 24-11, item 8.
Connect test box V.A.G 1598/31 to wiring loom to engine control unit page 24-12. Engine control unit is not connected.
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) 1 A A ( H G G F ' % 2 G R 1 1 A " ( H# G" G F & D 2 P R 3 ( H G 2 F $ 9 % 2 ( ( H G F $ 2 2 # ## 1 ( (# H 5 3Q G! D# 2 F F B # 6 A# # " A ' 2 '#Q D#I A## 6 I ! " 3# # 9 8 6 3 5 ! $ 2 !! 3 " 0 " 7 3 ' ) 1 ( 2 ( % ' & % $ " !@ !##!!! !!4 0 !! ! # ! ! ! #!0 !#
Special tools, testers and aids required
OCTAVIA
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24
8 ) ' ) E C F 8 % 3 6 3 3 & & P 0 5 D % 6 % 6 6 % 3 % @ 3 % & 4 % 6 3 % 6 G 4 C & & 7 % % % 6 &% C 5 H % 6 4 C & 9 % 6 3 & & ) E C F % 3 6 3 ' % 6 & G% 4 & G 0 0 9 % 6 3 % & )5 % E B CC & 9 8 3 6 3 %& 5 3 4 % % &C & A 0 F 9 % 6 T & & 8 ) 5Y ' ' % 6 $ " 0 5 6I' ) 8 F % 55% 6 33 & '& & &@ % 4 " 5 0% % )4 U 3 53 ' 59 % 3 " % 6 1 3 % " 4 @c3 '@` %U 7 B5A &W && &4 &1 &C ( C # $ A X $Q % & 5 5U 3 U D (9 6 2% b a #R #G !G S3 $U5 "
0
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24
Test procedure
OCTAVIA
P # " 1 % C D ' # # # & "1 % " " ! Q # " " ! # P 3 1 " 5 C C 5 H ' 0 B # 5 F1 7 # 1 5 F E ' 5 D C ' 0 B # 3 G 5 ' 7 # 1 @ 0 0 ) ) ) ) # A )( #G3 )) ) 6' 6 6 5 I 5 9) 5 2 $ )) (I # # $ #) & 4 2 ) # # # # '7 "7 " ! 1 0 8) 5 ) ) # ' " ) # # # & % ' " " ( $ 3 # & " !) " % ' $ ( " !
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OCTAVIA
K-
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24
2 u ' ( 3 1 ( 5 5 4 $ ( 1 # 7 u 2 $ ( 1 & & 3 & 3 # # 3 0 3 t " 4 r q H IG G V P1 p3 iF ` V I S H X T F H R H G I P d`v b a cF Y hv f eF cD W U g 2 2 2 1 & 3 3 ( @ 3 & 7 7 3 1 % $ &8 3 ( & @ # 8 2 # 9 & B & Q % 1 ( & # 7 6 4 5 2 ( 3( 0 & 1 PC %s%% %8 % ( %) &E s) #%8) %% '& $Q%)%%))8 4% %%% & & %' A%8 )%)&8% # w %% %& "%)P% %%E% % 8 %1 !)E
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24
loom, contact
OCTAVIA
OCTAVIA
24
coolant
t
and
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Test box 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
Connect vehicle system tester V.A.G 1552 and select engine electronics (address word 01); engine idling for this step page 01-2.
HELP
K Readout in display: -
Select function 08 Read measured value block and confirm the entry with the key Q.
K Readout in display: -
Enter 004 for display group 4 and confirm the entry with the key Q.
28.5 C
If an implausible readout appears in the display: Select function 06 End output and confirm the entry with the key Q. Switch ignition off.
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# # I % D % I $ $ # $ " Q " 33 $ % B 1 # ! " & $ U C 8 ) "T 6 R ' F S Q # I # $ % " " P 3# ! # $ # )# 1 0 % # I # $ 5 % " " 8 G 8 G ' 1 & D ! $ # # # $ 7 F 9 " 8 E 7 7 7 1 7 7 &$ D ! $ # # # $ 7 ' 9 " ! B & & 3 3 31 ! #@3 $3 3 3 # # 8 8 7 7 53 7C A 7 4 !3 ## $$ 33 $ E # $ # # 6 4 #H H ! ! # $ # $ !3 5 # $ # )39 13 1 09 % 2$ ( " & !@3 7 !3 # # $ ' % $ ! # % ! # " 5
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24
K-
OCTAVIA
OCTAVIA
page 24-14.
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24
24
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9 A b b v G C 9 c R R u r T S X T e Y CDH R 9 h I s C b R h I U Y 7 c A b a C 7 9 ` ` HH 9 A pd I 9 G q r S S Y 7 c A a C ` Hb 9h A9 R pD9 I9 I YH gi 7H 9d 9 R 9` a7 7`R B7 `Hd f@ S e Yc w 7` c` A9 a9 C7 79 9G dB x7 vS q9 yf `R `9 H7a WI9 XbP TCG SSb TR 9@C 9B RB BA Ptb 2Wb !8 ' !G "9 (e !q 3 FR CQWR CQQQ9 7Y 97 G7 9 I8Y 69 9D8DC ED8h 7QWI C 9I 7a Ba 4QW9D8Q8 5D88@D (Dw !8D@ 2t 1D8 !DQ !DCD (h 2@ 1& !! !)V 0% 0U $ " ' ' ( 3! #DQ& H# 0 % 0D8 A &8 0 @8 H # 8 & 0 @
Fuel Formation/Fuel Injection
OCTAVIA
T control unit
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Test box 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 T
at least 11 V
T -
Connect system tester V.A.G 1552 and select engine electronics (address word engine idling for this step page in
Test of
in
for display group 4 and confirm the entry with the in display
measured
28.5 C
(1 to 4
2.
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OCTAVIA
24
Press keys 0 and 6 for the function End output and confirm the entry with the key Q.
If the readout varies, or if the battery voltage is not achieved: KSwitch off the ignition. Connect test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12. Use the multimeter and adapter cables from V.A.G 1594 A to measure the supply voltage between sockets 2+62 of the test box: Specification: approx. battery voltage Switch on the ignition. Use the multimeter and adapter cables from V.A.G 1594 A to measure the supply voltage between sockets 2+3 of the test box: Specification: approx. battery voltage Repeat the tests at sockets 1+62 and sockets 1+3.
If the specifications are not achieved: Test the cable connections to the micro electrical centre according to the current flow diagram.
24
OCTAVIA
Switch on the ignition. Press keys 1 and 7 for the address word Dash panel insert and confirm the entry with the key Q. Press the key.
IMMO-IDENTNO: AUZXXXXXXXXXXX
HELP
K Readout in display: Press keys 1 and 0 for the function Adaptation and confirm the entry with the key Q.
K Readout in display: Press the key 0 twice for Channel number 0 and confirm the entry with the key Q.
K Readout in display: Complete adaptation by pressing the key. Press the keys 0 and 6 for the function End output and confirm the entry with the key Q. Switch off the ignition.
Note: When the ignition is switched on again, the code of the engine control unit is transferred to the immobiliser control unit.
OCTAVIA
24
------------
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24
OCTAVIA
Probe has been damaged by oil elements escaping from the crankcase ventilation, or by leaks in the engine. K Lambda probe voltage U in mV A: Lambda probe voltage high
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Test box 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 Test conditions l Engine at operating temperature l Basic setting o.k. l No leaks in exhaust system between catalytic converter and cylinder head
Lambda control switched off (engine control unit has detected a fault at the fuel injection system Interrogating fault memory and also Reading measured value block, display group 030).
OCTAVIA
24
Test procedure
HELP
------------
------------
K Readout in display: K Readout in display: K Readout in display: (1...4 = display blocks) Specification: 1 1 X
Connect vehicle system tester V.A.G 1552 and select engine electronics (address word 01); engine idling for this step page 01-2.
Press keys 0 and 8 for the function Read measured value block and confirm the entry with the key Q.
Press keys 0, 3 and 0 for Display group number 030 and confirm the entry with the key Q.
If the specification is not achieved page 24-46, Testing lambda probe cables.
Note:
The Lambda probe status indicates the status of the lambda control and of the lambda probe.
Meaning of the 3-digit readout of display group 030 1 1 1 1 Display block 1
If the specification is achieved, but a fault is stored in the fault memory: Test lambda probe control page 24-44.
24
Testing lambda probe control Press the key C. K Readout in display: Specification for display block 1: Switch into display group 031 as follows: Press the key C. K Readout in display: Specification for display block 1:
OCTAVIA
Enter 033 for Display group number 033 and confirm the entry with the key Q.
Press keys 0, 3 and 1 for Display group number 031 and confirm the entry with the key Q.
The voltage must vary about 30 times a minute within the range 0.00...1.00 V. If the specification is not achieved analysis of display group 031, page 24-45.
OCTAVIA
24
constant 0.40...0.50 V
constant 0.00 V
Continuation If the specification is not achieved in display block 1, or if the readout does not vary by at least 2 %: Conduct a road test in order to eliminate any residues on the lambda probe, and repeat the test.
If the specification in display block 1 is also not reached after a road test, or if the readout does not vary by at least 2 %: Test the basic voltage page 24-46.
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24
OCTAVIA
Testing basic voltage KSeparate the 4-pin plug connection to the lambda probe. Connect the multimeter for voltage measurement between contacts 3 and 4. Switch on the ignition. Specification: 0.400 ... 0.500 V Switch off the ignition.
If the specification is not achieved: Test the lambda probe cables page 24-46.
If the specification is achieved: - Replace the lambda probe. 1.4-ltr./44 kW Engine, Mechanical Components; Repair Group 26; Removing and installing parts of the exhaust system
Testing lambda probe cables Separate the 4-pin plug connection to the lambda probe. Connect the test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12. Test the following cable connections for open circuit:
K-
------------
------------
If the cable connections are o.k.: Replace the engine control unit page 24-14.
OCTAVIA
24
Continuity test K-
Use the hand-held multimeter to conduct a continuity test (resistance measurement) between contacts 1 and 2 of the probe connector.
Note:
At room temperature the resistance of the heating element is about 1...5 . The resistance rises sharply even if there is only a slight increase in temperature.
If any open circuit is found, replace lambda probe (G39).
If the heating element has continuity, test voltage supply for lambda probe heater (Z19) as follows:
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24
OCTAVIA
Testing voltage supply KUse the adapter cables from V.A.G 1594 A to connect the multimeter for voltage measurement to contacts 1+2 of the connector. Start the engine and measure the voltage. Specification: approx. battery voltage Switch off the ignition.
If no voltage is present: Connect the multimeter to contact 1 of the 4-pin connector and to earth. Start the engine and measure the voltage. Specification: approx. battery voltage Switch off the ignition.
If the specification is not achieved: Test the cable from contact 1 to fuse 43 for open circuit.
If the specification is achieved: KConnect the test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12. Test the cable from contact 2 of the 4-pin connector to socket 4 of the test box.
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OCTAVIA
24
Use the hand-held multimeter to conduct a resistance measurement between the contacts of the valve.
Specification: 22...30 -
24
OCTAVIA
Note: The voltage for the ACF valve is supplied through the fuel pump relay.
Test condition K l Fuse 43 o.k.
Test procedure KUnplug the connector at the ACF valve. Connect the diode test lamp between contact 1 of the connector and engine earth. Operate the starter.
Specification: The diode test lamp must come on. If the diode test lamp does not come on, test the cable connection from contact 1 to fuse 43 for continuity; repair if necessary. Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder If the cable connection is o.k., test fuel pump relay page 24-27.
Testing actuation of the ACF valve KConnect the diode test lamp between contact 2 (earth actuation of the engine control unit) and positive terminal of battery. Initiate final control diagnosis and select the activated charcoal filter solenoid valve (N80) page 01-30.
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------------
Specification: The diode test lamp must flash. If the diode test lamp does not flash or if it comes on and remains on: Switch off the ignition.
OCTAVIA
24
K-
Connect the test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12. If the diode test lamp came on and remained on, test the cable from contact 2 of the connector at the ACF valve to socket 61 of the test box for short to earth. If the diode test lamp did not flash, test the cable from contact 2 of the connector at the ACF valve to socket 61 of the test box for continuity and also for short to positive. If there is neither an open circuit nor a short circuit in the wiring, replace engine control unit page 24-14.
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OCTAVIA
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24
It would be incorrect to believe that the electronic throttle system consists of only one or two components. Rather, the electronic throttle is a system which embraces all the components which contribute to determining the position of the throttle valve, to controlling and monitoring it (e.g. the accelerator pedal position sender, the throttle valve control unit, the EPC warning lamp, the engine control unit ...).
Function of the EPC warning lamp (fault lamp for electronic throttle control) in dash panel insert
EPC is an abbreviation which means Electronic Power Control (electronic throttle). K Fitting location of EPC warning lamp The engine control unit checks all the principal components involved in the function of the electronic throttle system after the ignition is switched on. During the check of these components, the engine control unit switches on the EPC lamp for about 3 seconds. If a fault is detected during this test, the lamp remains on. If faults are detected in the electronic throttle system during operation of the engine, the engine control unit switches on the EPC lamp (these faults are stored in the fault memory). In the event of an open circuit in the wiring or a fault occurring in the electronic throttle system, the engine switches into the emergency mode. In the emergency mode, the engine runs at fast idling speed to allow the customer to drive the vehicle to the nearest workshop. The accelerator pedal position senders do not operate in this case.
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24
OCTAVIA
The EPC warning lamp must come on. Start the engine and run at idling speed.
The EPC warning lamp must go out if no fault relating to the electronic throttle is stored in the fault memory. A - Fault lamp for electronic throttle control -K132- does not come on KConnect test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12. Bridge sockets 1 and 73 of the test box. Switch on the ignition.
The fault lamp must come on. If the fault lamp does not come on: Switch off the ignition.
- Test the dash panel insert. Electrical System; Repair Group 90; Dash Panel Insert; Removing and installing dash panel insert
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If no fault is found:
OCTAVIA
24
Test the following cable connection for open circuit and short circuit to positive: Test box V.A.G 1598/31 Socket 73 Dash panel insert Contact Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
If the cable connection is o.k.: Replace the engine control unit page 24-14.
B - Fault lamp for electronic throttle control -K132- comes on and remains on Interrogate the fault memory of the engine control unit page 01-4.
If no fault is stored: KConnect test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12. Test the following cable connection for short circuit to earth: Test box V.A.G 1598/31 Socket 73 Dash panel insert Contact Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
If the cable connection is o.k.: Replace the engine control unit page 24-14.
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24
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% & $ # $ # " !
Fuel Formation/Fuel Injection
OCTAVIA
control unit
The following components are integrated in the housing of the throttle valve control unit:
Throttle valve drive -G186-. (This is an electric motor which is operated by the engine control unit. This electric motor opens the throttle valve by overcoming the force of a spring.) Angle sender -1- for throttle valve drive -G187 Angle sender -2- for throttle valve drive -G188Notes:
The housing of the throttle valve control unit must not be removed.
The angle senders are designed as potentiometers (variable resistors). The senders supply the position of the throttle valve to the engine control unit; each sender does that independently of the other. The potentiometers cannot be set mechanically. Setting is performed with the vehicle system tester V.A.G 1552 in function 04 (initiating basic setting).
When adaptation is performed, the engine control unit learns various positions of the throttle valve with the ignition switched on and the engine not running. These positions are stored in the engine control unit. The feedback regarding the position of the throttle valve is provided by the two angle senders for the throttle valve drive. If the throttle valve control unit and re-installed, or replaced, or if the voltage supply of the engine control unit is interrupted, it is then necessary to carry out adaptation.
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OCTAVIA
Fuel Formation/Fuel Injection The learning process (adaptation) is performed: by initiating the basic setting (function 04) display group 60, ignition on. automatically, if the ignition is switched on for at least about 6 seconds, without operating the starter and accelerator pedal, and the engine control unit detects learning demand. (In this case, it is not clear whether adaptation was successful or not). Learning demand is detected in those cases where stored voltage values from the angle senders do not match with currently measured voltage values within a certain tolerance range. Note: The engine does not start during automatic adaptation. Special tools, testers and aids required Vehicle system tester V.A.G 1552 with cable V.A.G 1551/31 Requirements: l No fault stored in fault memory; interrogating fault memory page 01-4. l Engine not running, ignition on. l Accelerator pedal not depressed. l Coolant temperature higher than 5 C, but less than 100 C. l Intake air temperature less than 100 C. l Battery voltage at least 11 V. Procedure Connect vehicle system tester V.A.G 1552 and select the engine electronics control unit (address word 01); ignition switched on for this step page 01-2.
24
HELP
K Readout in display: Press the keys 0 and 4 for the function Basic setting and confirm the entry with the key Q.
24
Basic setting Enter display group number XXX
OCTAVIA
Enter 060 for display group number 60 and confirm the entry with the key Q.
After pressing the key Q, the throttle valve positioner is first of all de-energized. In this state, the throttle valve is pulled into an emergency running position by a mechanical spring integrated in the throttle valve control unit. The values which the two angle senders supply in this emergency running position, are stored by the engine control unit.
After this, the throttle valve is opened by a certain amount. Once this value is reached, the throttle valve positioner is again de-energized. Now, the mechanical spring must close the throttle valve within a certain time to the previously learned emergency running position (test of spring). After this, the throttle valve is closed by the throttle valve positioner; the values which the angle senders in the throttle valve control unit supply, are stored in the engine control unit. If the engine control unit de-energizes the throttle valve positioner when driving, this makes itself noticeable by a fast, surging idling of the engine. The engine then has only a very slow throttle response. 0 K Readout in display: Check the specification for the throttle valve control unit in display block 4. . . Specification in display block 4: Note: The abbreviation ADP in display block 4 means Adaptation.
Edition 06.00 S00.5126.51.20
OCTAVIA
Fuel Formation/Fuel Injection Note: If adaptation is aborted by the control unit, the reasons for this may be as follows: The throttle valve is not able to close fully (e.g. dirt). The battery voltage is too low. The throttle valve control unit or the cable connection is faulty.
24
HELP
------------
HELP K Readout in display: K Readout in display: 7.0 % K Readout in display: Note: Check display blocks 1 and 2. Slowly depress accelerator pedal fully. Notes:
------------
24
OCTAVIA
Press the keys 0 and 8 for the function Read measured value block and confirm the entry with the key Q.
Press the keys 0, 6 and 2 for Display group number 062 and confirm the entry with the key Q.
Check the specifications for the potentiometer voltages of the electronic throttle.
The engine control unit converts the voltage values of the angle senders into a percentage based on 5V and indicates these percentages (5 V supply voltage equals 100 %).
The percentage readout in display block 1 must rise evenly. The tolerance range of 3...93 % is not fully utilized in this case. The percentage readout in display block 2 must drop evenly. The tolerance range of 97...3 % is not fully utilized in this case. The reason why the readout in display block 1 rises, and the readout in display block 2 drops in contrast, is due to the contrarotation of the potentiometers (angle senders) in the throttle valve control unit.
What this means is that the voltage tapped by the one angle sender moves in the direction of 5 V. (The more the throttle valve is opened, the greater is the voltage; the percentage readout rises). The voltage tapped by angle sender 2 moves away from 5 V in the direction of 0 V. (The further the throttle valve is opened, the lower is the voltage; the percentage readout drops).
OCTAVIA
K-
K-
Y W v " W v " ! u R & X X V U T Y" W t E A r E s I q Q ! ! # " p " Q " " ! & ! i " # " " ' Q" & ' " X V " V e W " b " " X X V U T g W W Q R & X X V U T Ya W T X V U W T g e b W XS V UE U T c b W U a P ' R R ! X'' V U U T ` Y W a " " Cw G C ES C A E A C F I H 4 1 0 8 6F' 4 7 7F 1'' 5 4 0 2 3C 3@ ) % 'h ! ' ' Q # # Q Q Q ! $ " % SB' ' !1 @' 'Q ' !@ f ' ' 0 f W" bD ` X W Yd W Y b1 c b W W''9 g h b& Y b@ W C3 E y t @ q2 x ! # ! ! & " B " '( $
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24
Special
connection Contact
accelerator pedal
and
required
OCTAVIA
OCTAVIA
X & X ' ` h u r 3 8 h 2 s 3 5 r s 3E 8 8 C5 E3 H C h 8 5 2 E 6 C H h 8 3 7 ip q i p A f e d ) X $ ` i X2 ` e ) 1 1 c2 d8 bg ' a ` t W ` Y V 11 Xw W 8 H P 3 C S R R Q T IA 21A H Cb 8 2 C E C GU F2 A @8 3ED 9C 8D 6v 3 3 2 5 4 7 1B DX 7DB 4 B7 ! D!B1 !4 !B1 ( 0 D71 # $ # ! ( ! ! ) ' & ! $ # a !! " D E U %!c !d "!1 DB@! D1 d y! x ` Y
Fuel Formation/Fuel Injection
24
cle systems
K Readout in display: -
and
Read en-
6 and 2
Display group
Q.
62
electronic
potentiome-
Note:
The engine control unit converts the voltage values of the senders into a related to 5V and these percentages V voltage display and
percentage readout in display tolerance range rise evenly. in t case. not ully u
must is
percentage readout in display must rise evenly. tolerance range is not u in case.
Note:
est voltage supply and cable connections accelerator pedal position senders page
------------
------------
r s s e e r e b r e P h w b v b ` a y b t g Y # % 6 1 1 # % H % T T % 5 6 2 1 ' 4 ( ( 4 q 6 # 0 % % 6 % W # 6 6 % T # 1 T C 6 2 T % % # ) #H C2 1 0 $ 6 H % 6 % # 6 C 6 T # # % ( X U5 W# # % 2 % # d e ' G ( u b f h w v b ) t # C 1 0 # 6 # r s r g 64 %2 %& 0 1 5 # 0 % 1 # # 1 # T T % 6 % 6 % '' 4 ( q $ #% 62 C# 6 # # % 6 % # 5 6 6 % T # 1 T # T ( ) # # 1 & % 6 T # 1 6 % 1 5 4 ( 6 % # 1 5 1 6 C T # 5 # 5 ) ( # # 1 & # 1 T 6 % 1 5 4 ( V' %0 0 0 1 d% 22 c eB0 h f g V %T 0T 02B8 1'2 dr 2' 1 # c e3T g f ( VB'5 %6 02B37' 0'2'B 1'B3 d% 2T c e4 e7 f(BB b V6B %# 0x7' 05 1B7U dC 2T 1' #' c e6 (' f# b a `UB'V H7B % b 5 8'V' 8V' 7BT g Y 5 ( '5 g W $ % % 5 1 X U# # $3' $2 $ #0 HBV'7' 1( # # 5# CV 1' % % # & # 2BT H # 2 ( S W 62 %'' 6B7 C # 6 % ( ( #' 6 # 6 % 5 % 0 1 5 # 0 2 1 4B7' 4 S U# #6 1( #5 T% T6 %'3i 6BB % # 6 6 % T C H 0 T # # 2 1 0 # ' (2'B3 ( 71 "B' $ #% 61 15 0# 12 C 6 5 1 6 6 1 5 C 6 % # & # 6 1 ('' 47 4 R 74 "' 9 1 0 # @ 1# 56 0 H % % C 6 F3 I5 D'B QTi G7'B (6 PVBp A E 4 # " #2BB3 6Ti 16 0% $ #787B' %' 1B 0 # # # & 2 $'BB' 1''3 522 % % (3 ( 7% (T 4''B' ) ! (B '7V 2B2 'BF2 3''' 7 ' B''F7 277' 'BBBB8 'B' 'B '7 ' ' 7 32 !% # 27' B'3
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24
K-
K-
connection
connection
OCTAVIA
OCTAVIA
24
Testing engine speed signal: Current Flow Diagrams, Fault Finding and Fitting Locations binder
24
------------
A I G H 9 4 D C 4 E F A B 4 9 8 4 ' 0 ( $ $ ) 0 3 $ $ ( ( $) $ $ )3 $ $ '5 4 5 $ $ @ %1 2 6 & !7 # " 7 7 66 4 7 4
Fuel Formation/Fuel Injection Notes:
OCTAVIA
The
The 9 of
he
he
l Operation and indication of speedometer o.k.; fault finding: Electrical System; Repair Group 90; Dash Panel Insert; Testing vehicle speed signal
Connect vehicle system tester V.A.G 1552 and select the engine electronics control unit (address word 01); engine idling for this step page 01-2.
Warning!
Please observe the safety precautions to avoid risks of accidents when conducting measurement and test runs page 24-1.
HELP
K Readout in display: -
Press keys 0 and 8 for the function Read measured value block and confirm the entry with the key Q.
K Readout in display: -
Press keys 0, 0 and 5 for Display group number 005 and confirm the entry with the key Q.
Idling
K Readout in display: -
Conduct a road test to determine whether the vehicle speed is displayed in display block 3.
If the vehicle speed is not displayed, raise vehicle -with a lift platform if possible- until the left front wheel is clear of the ground.
------------
OCTAVIA
24
K-
Connect test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12. Connect the diode test lamp to socket 3 (positive) and socket 9 (vehicle speed signal) of test box V.A.G 1598/31. Switch on the ignition and rotate the left front wheel by hand.
The LED must flash (very brief flashing signal). If the LED does not flash: Test the following cable connection for open circuit and for short circuit to earth and to positive: Test box V.A.G 1598/31 Socket 9 Dash panel insert Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder Contact
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`(I " Q
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24
1000
Testing switch
Test procedure
If the brakes are applied when the accelerator pedal is constantly depressed, the engine is immediately governed to idling speed. A faulty brake pedal switch can result in unintentional governing of engine speed.
The command from the accelerator pedal position sender (potentiometer) to the engine control unit to open the throttle valve is suppressed for safety reasons if the brakes are applied. The brake light switch signal and, in addition, the brake pedal switch signal are required in the control unit for this purpose.
Note:
Connect
on
not
on
en-
OCTAVIA
2 V X W A ! & 0 d # 6 G P c R b ` P S C D R C a H S E Y 2 V X W 0 d # " G P c R b ` P S C D R C a H S E Y ! % ' ( # # T T S U H D P C R H G D 9 # @ % ! ' ( A ' ' #% 3 % 3 9 # E E 0 ' & 1 2 Q ' ' # 3 4 ' 5 " & ! E 7 #BE 6 I F Q8 (Q Q C ' %E E 4 ' 5 " & 2 8 ' # 3 ( 0 ' 1) & ! $ #% " ' %% % ( %( ( ) % %
T Connect Connect Connect on connection connection not
-----------------------
OCTAVIA
K-
KK-
24
------------
If the LED does not come on: Test the cable connection from contact 1 or 2, respectively, of the connector for open circuit and for short circuit to earth: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder Rectify any open circuit or short circuit in the wiring. If the LED comes on: T actuation KConnect test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12. KTest the following cable connections for open circuit and for short circuit to earth and positive: connection Contact 3 4 Test .A.G 1598/31 Socket 63 53 Rectify any open circuit or short circuit in the wiring.
-----------Edition 07.99 S00.5126.50.20
24
OCTAVIA
OCTAVIA
24
Testing
Hand-held multimeter (e.g. V.A.G 1526 A) Diode test lamp (e.g. V.A.G 1527 B)
Adapter cable set (e.g. V.A.G 1594 A) Test box V.A.G 1598/31
Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Note: This signal is used for avoiding the engine overrevving and load change jolts when the clutch is released. T -
Connect vehicle system tester V.A.G 1552 and select the engine electronics control unit (address word 01); ignition switched on for this step page 01-2.
HELP
K Readout in display: -
Press keys 0 and 8 for the function Read measured value block and confirm the entry with the key Q.
K Readout in display: -
Press keys 0, 6 and 6 for Display group number 066 and confirm the entry with the key Q.
0000
K Readout in display: -
Check the readout for the clutch pedal switch in display block 2. Specification:
------------
------------
4 " ! ' 9 ' ' 4 ' E H I' F #3 R S 8 g P f y x P ' & E B t ' " & 4 ' E ' " 4 ' ' ' # s 2 % 2 % w H 9# "4 " F E E " 4 & " # ' ( 2Q t B 2 " 9 I& Es & ' " 9 ' #% E ! E #' " # ! 9 % 3' $ # 933 9 & 4 9 ' ' E $ 1 "v '3 ( E E ' ' ' E " E E P# $ r ' ' E B t % s G 'G 9 E & B t r s D F ' 'I 4 ' 0& "P E 1E #Q (& %(G P ` G b p i#3(3 c h F & 0 H G( "9 &! 4 " & ' # E @ S$ 8# g) f QE P$ d d$ cX e ` b 3u 3# "3( ' E " & ! E %333 # GE F#3 E3) "#( ! & 9 E E " 3# %$ # 3 " ' E ' " & E %( D 9G '$ 'X 1 ' E ' " ! E W) " ! 9 E E & % B D 3 " ' " ! E R S33 T P3 G F ' " " ' & E ' E ' 9 Q % P H I ) " & G &! ' " E & & 9 ' F E & D 9#a E! EE " ' ' ' E 4 9 ! E " " ! % ' & (V $ "(( 'E " !! "T 4 ' &# "$ '$ '3 "3 & 4 ' ' " %3 %) C ( 0 "(($ !((# # 1 " &! !G3 93 3# 4 ' 7 @& 5$ BE 8 ' AE 2 6 % 3$3) # #3(3 'E "' !#73 ")3) &3 33G " !3 # a # 3(GG$ E %a)7 (Y $((( 3(3( 333 X 3 33(3($ 33X 3$
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24
K-
K-
actuation
connection
easure to
OCTAVIA
` ` ( f # h x ! " ! ( f h # x ' ! ( # # ( D $ ` " ` " " # D # ' ( " " # s # x D ' ! ( # # ! g e x ! ( # e x # # " ( % w ) ) ` ( % f f d c b g eD W G R F G H X f f d c b u e e D ` f f d # c b g e b f d) c e b u s p e # ( # ! f d c cg b" q p % e! c i # Y" ) # D " `` ` "! fj d` c c& bj h g" ej i#' # F W( V) G G U R R U S E X " " D h #j Y j S ) ) G" % ! ) ( # ( ` " " "&i g " ! ! # U 2 B C @ C 0y 0 2 6 3ia 1 3 4U 3)a 54v 5$ 4 ' )tt) " ) ) ) " ! ( P ) f9 h)) g R( G Hr e R P v E)$ f d # R) a W H G ) $ " 7 !H I 5 TQ ") #8 A # # ! % v A v Q I Q &
Fuel Formation/Fuel Injection K K KT
OCTAVIA
Testing
connection
steering
Test
------------
------------
24
------------
00000 K Readout in display: Check the readout for the power steering pressure switch in display block 4. Specification: 0XXXX (when steering straightahead or turned slightly) 1XXXX (when steering turned to full lock) If the readout does not appear as described: T KSeparate the plug connection -2- at the power steering pressure switch (F88) -1- at the power steering pump. Connect the multimeter for resistance measurement to switch -1-. Start the engine. Specification: (no continuity) Turn the steering wheel to full right or full left lock. Specification: max. 1.5 If the readout does not change: Replace the power steering pressure switch -F88-. If the readout changes: Test the cable connections connections page 24-74. T KConnect test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12.
-----------Edition 07.99 S00.5126.50.20
24
OCTAVIA
OCTAVIA
24
K-
Test the following cable connections for open circuit and for short circuit to earth and to positive: Contact at plug connection 1 2 Test box V.A.G 1598/31, socket 30 47
2 - ABS control unit Located at hydraulic unit in engine compartment 3 - Databus driver Part of control unit Models 04.99
1
CAN_High
R1
K Terminating resistor in engine control unit is 66 . K Terminating resistor in ABS control unit is 2.6k . Function
CAN_Low
S24-0437
The engine control unit -1- communicates with the ABS control unit -2- over the databus.
At least two databus-compatible control units are linked over two twisted databus lines (CAN High and CAN Low) and exchange information (messages).
24
OCTAVIA
Information which is not supplied over the databus, is recognised both by the engine control unit -1- as well as by other CAN databus control units as a fault (e.g. ABS control unit -2-). A terminating resistor R must be positioned upstream of the bus driver -3- in both control units to enable the CAN databus to operate properly. For further information: Self-Study Programme 24 The CAN Databus, Design and Function. 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 1598/21 Test box V.A.G 1598/31 Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 Read out fault memory of ABS control unit.
------------
Switch ignition off. Connect test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12. Engine control unit is not connected for this step. Test databus lines together with terminating resistor in ABS control unit. Measure resistance between test box sockets 20 and 21. Models 04.99 Specification: 115...135 . Models 05.99 Specification: 2.3...2.6 k . If the specifications are not achieved:
-----------Edition 06.00 S00.5126.51.20
w $ 8 ( 1 & F ( D ( E C Q H G E 8 & B & F D C H G$ E ' ( ! I % 8 ' ' " & ! 8 # & ( ! ( # " 9 $# E ) & A 5 4 v 2 2 @ # & t F P D v D u ! 8 ) ( % ### ##$ ## $ #$ & & #0 (#& ( ' E## P# E P E E W& S q#I T& W S q T U r r i a W## X#& T S X d d b$ ` c Y ps f e cU# V b R ` c Y h f e gW c V R 9 " 8( # # ( F& F D## C H G D E E P C H G E I1 ' E& Q % 8) & & && & & & & & ' ' ' T !# # (0 " # S #$ B & F D ($ E C P H G E 4 ' I ##t## 1 & & ( ( & ' A 5 9#$# 8 & 5# B 6 5 4 5 2 $3 ( 6# 40 5 1# ) ## & & # ( ( ! % ( #U #$ga #U i & & # & #$# & # $ ( '# # ($ ' $ " 0 #### &# #@## $#)$ ### ## #) $ #$# # # # # !I#0 )
R .
------------
OCTAVIA
K-
------------
24
S I R 8 E Q8 " Q H 9 $ G G 8 D E # C 7 ( 2 0 B ' 6 6 ) 8 @ @ A " " " 7 3 ( ' ) 6 6 4 & " $2 #" " ! % 8F 0 % % 5 1 1 % % 9 9 3 5
------------
------------
24
Test
OCTAVIA
OCTAVIA
Ignition System
28
When conducting certain tests it is possible that a fault is detected and stored by the control unit. For this reason, always interrogate the fault memory and erase it, if necessary, after completing all the tests and repair work. If the engine starts only for a short time and then cuts out again after completing fault finding, repairs or tests of components, the reason for this may be that the immobiliser is inhibiting the engine control unit. In this case, it is then necessary to interrogate the fault memory and, if necessary, to adapt the control unit.
Safety precautions
Pay attention to the following points in order to avoid injuries to persons and/or damage to the fuel injection and ignition system: Do not touch or disconnect ignition cables when the engine is running or operating at starting speed. Do not disconnect or re-connect cables of the ignition system -also not cables of hightension and test equipment- unless the ignition is switched off. To operate the engine at starting speed without it actually starting (e.g. testing compression), unplug the connector from the ignition unit and the connectors of the injectors. After completing the work, interrogate the fault memory and erase it. Do not carry out an engine wash unless the ignition is switched off. Do not disconnect or re-connect the battery unless the ignition is switched off otherwise the engine control unit may be damaged.
Ignition System
OCTAVIA
Ignition timing cannot be adjusted, is determined by the engine control unit Firing order Spark plugs Manufacturers designation Electrode gap Tightening torque Change interval
1-3-4-2
60 000 km
OCTAVIA
7 6 5 3 3 B & F E C @ 2 2 4 3 & " 2 2 4 3 & 1 " 2 B 2 3 B 4 & C A D ' 3 8 # @ 9 ( 7 6 5 2 2 4 3 & " 1 0 )! $ $ % & # ' ( " !
Ignition System
28
ignition system
Ignition Testing ignition unit page 28-4 Ignition transformer with power output stage -N152-
25 Nm Inspect for cracks, traces of creep current Inspect wear of contacts Clean before fitting on
6 20 Nm It is essential to tighten to the correct torque as this affects proper operation of the knock sensor Testing page 28-8
8 9 Nm
0 C 2-pin For engine speed sender -G28Engine speed Testing page 28-10
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------------
28
Ignition System
OCTAVIA
------------
Use the multimeter and adapter cables from V.A.G 1594 A to measure the supply voltage between contacts 2 + 4 of the unplugged connector. Switch on the ignition. Specification: approx. battery voltage Switch off the ignition. If no voltage is present: Test the cable between 4-pin connector contact 4 and earth for open circuit according to current flow diagram. Cable resistance: max. 1.5 Test the cable between 4-pin connector contact 2 and microelectrical centre for open circuit according to current flow diagram. Cable resistance: max. 1.5
-----------Edition 07.99 S00.5126.50.20
OCTAVIA
28
When conducting the following test, do not touch the connection parts of the ignition coils or the test cables. KUnplug the connectors from the injectors Unplug the 4-pin connector from the power output stage for the ignition coils. Use adapter cables from V.A.G 1594 A to connect the diode test lamp to contacts 1 + 4 (ignition output 1), contacts 3 + 4 (ignition output 2) of the unplugged connector. Operate the starter and test the ignition signal of the engine control unit. The LED must flicker. Switch off the ignition.
If the LED flickers and voltage is present between contacts 2 + 4: Replace the ignition unit page 28-3, item 1.
If the LED does not flicker: KConnect test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12.
K-
Test the cables between test box and 4-pin connector for open circuit according to the current flow diagram. Contact 1+socket 112 Contact 3+socket 113 Cable resistance: max. 1.5 In addition, test the cables for short circuit to each other. Specification:
If no fault is found in the wiring and voltage is present between contacts 2 + 4: Replace the engine control unit page 24-14.
------------ 28-5 ------------
28
Ignition System
OCTAVIA
------------
------------
$ ) A @ A T B # 1 $ # ) # $ $ ( ) # # # 1 ! 1 7 ( B # 1 ! 1 # % % $ @ @ @ E # ) P 9 @ T $ ! 3 Q R @ 8 # V ` ) X c a V V V $ % #" $ 1 ! ! % 7! U ! # ! ( $ # # ! $ ) # % ! ! F T $ $# )54 #" 1 $ # ) # $ 0 4 ! G ($ % $ P C& I @ H E R Q @ F ' ( #"2 ! # ) ! $ $"6 3 $ # ! 7"""2 & B 4" 4 !"%"% #e $% # ! ! % C"d""" E8 D! @$ $ ! 1 7 $ ) # A @ 9 d 2" $ # )A #T $% !e ! $ 8e 1 $ ) ! % 2d " " $ $ 3 $ # ! 5 W 7 $ 7 3 "55 $# )$ !$ $5 3$ 8! !%% G $" %@ ! 3 $ %% b FS% 2# F "" " & ! G$ % $ b P"1 H!"" T & !# G) % $ b P"4 H22 @ V & ` a V12" `# "" E %W 4% V V V X&" Y# W W! W& ( ! ! # "&2"" 0 4$ "" $&%5 1! $ $"% ! )%"" !" $ 3 $ %" 1 $ # ' ( #""" !"6 # )2 " !2 # % % " &&2 #86 !# !# "" %" $ &% ""% "$ 22 "$ 22 "2 "6 2" 6
T the no Unplug the connector control Plug Plug the the on the the the the t to the the open the p the control not control or or Test box V.A.G 1598/31 to the to the p
------------
OCTAVIA
Ignition System
K-
K-
open to
the
------------
28
28
Ignition System
Testing
Hand-held multimeter (e.g. V.A.G 1526 A) Adapter cable set (V.A.G 1594 A) Current flow diagram Notes: The
Test
& $ # # $ P ( ) ) X ) 1 ) 0 ) ) ' ' )( ) ( 2 1 ) ( 1 ) 0 ( ) 2 ( ( 3 ) 0 H Q I 0 9 2 I ) E I 2 B ' ' P )2 ) ( 189 2 1 ) ( 1 2 0 3) ) 2 Q V ) ( 93 W R 4H 2 2 ) U 1 B 2 E ) 0 B T ( 2 2 (( 2H H1 2 9 C R1 R ( 2 '9 '` H ( )I (2 2 0B )" ) 2 1 ( ( ) 0 2 B 0 2 0 9 R9 C R G P )33 20 Q1 2F 1 B E B ( ) 1 3) 0 2 B 0 I ) H ( DAA C3 D A2 D 2 2 B E 2 2 0 0 D ' )4" (8' (E B1 04 ) ( 2 1 ) ( 1 0 3 29 19 9I 5 CI 7 6 &1 %1 "9 @9F3 #3 3 "1 "93 @3 $A3A $3 $4 98A9 8 @8988 @ 3 99S 388 A9 @9@@@9 9 @@3 S F! @8@88 9@889F9
OCTAVIA
e 20 Connect test box V.A.G 1598/31 to the wiring loom to the engine control unit page 24-12. Test the cables of the knock sensor for short circuit. Sockets: 101+109 Specification: Unplug the connector of knock sensor 1 -G61-. Test the cables between test box and knock sensor for open circuit according to the current flow diagram. Contact 1+socket 109 Contact 2+socket 102 Contact 3+socket 100 Cable resistance: max. 1.5
Edition 07.99 S00.5126.50.20
G 9 3 ( " D 6 0 3 F 8 3 3 ) ( ( # 3 3 " E 1 1 D C ( 3 " ' ' @ B ' B A ' " ( ' ' 3 3 @ ( " ( ' 8 3 " ' # & 4 1 6 4 3I 3 3 " " 3 ( ' ' 3 9& ( " ( " '$ 5 4 % # '&&& ' ) 3& 2 1 0 ( 7 &$& # # ' ! @ ( # && $ ' # " $ ! # #& # &&&% & &&# &#& & $&&&& % # &
t t
-----------------------
OCTAVIA
Ignition System
28
28
------------
C aF E4 5IF 2 9 2 2 P X 9 Q Y W ` 2 P H 2 9 2 2 P X 9 Q Y W F 4 P 2 H 9 9 U S R T S S R G D E F 2 2 2 C B 2 A6 4 96 9 1 8 2IIQ3 76 2 4 0II@3 IV #V (3 06 ) & $ ' $ &6 & $ # # $ ($ ( ( " 6 "! 5" 53 " 5 % @ 2 &! &
Ignition System
OCTAVIA
Testing engine
Hand-held multimeter (e.g. V.A.G 1526 A) Adapter cable set (V.A.G 1594 A) Test box V.A.G 1598/31 Note:
If no signal is received from -G28- when the engine is running, this immediately results in the engine stopping. The engine control unit substitutes the signal from the engine speed sender G28- with the signal from the camshaft position sensor -G163-. The engine can be re-started and runs at a fast idling speed in the emergency mode. T -
conducting the ensure the installed and tight. sender is nplug the 2-pin connector -2- from the engine speed sender -1-.
K-
onnect the multimeter for resistance measurement contacts 1 and 2 at the sender -1-. ...
Note:
The resistance of the engine speed sender is based on a temperature of 20 C. The resistance becomes greater as the temperature rises. the specification is not
the specification is
K-
test box V.A.G 1598/31 to the ing loom to the engine control unit page 24-12.
------------
% ' 7 ! 6 0 6 1 " ! " " 2 1 0 % ! ! ! ' f3 e 0 1 d 3 0 C& E B D C F b c ` Q R C$ P D C D D C B E A @ B U TB Ya W V T I H X! 8 S ! " 3 ) F( !F & " " ( G4 F 5 $ ' 9 #
est
------------
OCTAVIA
Ignition System
K-
V.
------------
28