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Octavia 1997
Octavia 1997
1.6 l/75 kW Engine, Fuel Injection and Ignition System
Edition 06.01
Supplement 1 2
Subject Basic Edition Changes for engine BFQ Modifications in Rep. Gr. 01 24 and 28
List of Supplements
Octavia 1997
List of Supplements
Octavia 1997
Table of Contents
01 Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 - Operation ............................................................................................... 01-1 - Technical data of self-diagnosis ..................................................................... 01-1 - Connecting up the vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics ..................................................................................... 01-1 - Interrogating and erasing fault memory ............................................................ 01-1 - Performing actuator diagnosis ....................................................................... 01-1 Self-diagnosis II ......................................................................................... 01-2 - Fault codes 16486 16990 ......................................................................... 01-2 Self-diagnosis III ........................................................................................ 01-3 - Fault codes 17040 18088 ......................................................................... 01-3 Self-diagnosis IV ....................................................................................... 01-4 - Readiness code ........................................................................................ 01-4 - Reading readiness code .............................................................................. 01-4 - Generating readiness code .......................................................................... 01-4 Self-diagnosis V ........................................................................................ 01-5 - Reading measured value block ..................................................................... 01-5 - Display groups 001 up to 028 ....................................................................... 01-5 Self-diagnosis VI ....................................................................................... 01-6 - Reading measured value block - display groups 030 to 132 ................................... 01-6 page page page page page page page page page page page page page page page page page page page 1 1 1 2 3 4 1 1 1 1 1 1 1 2 1 1 1 1 1
page 10
Table of Contents
Octavia 1997
1.6 l/75 kW Engine, Fuel Injection and Ignition System page page page page page page page page page page page page page page page page page page 2 3 1 1 1 3 1 1 1 2 4 6 6 7 1 1 2 3
- Testing lambda probe -G130- and lambda control downstream of catalytic converter ..... 24-4 - Test of ageing of lambda probe upstream of catalytic converter -G39- ....................... 24-4 Electronic Engine Power Control (Electronic throttle) ........................................ 24-5 - Inspecting fault lamp for the EPC ................................................................... 24-5 - Testing throttle valve control unit -J338- ........................................................... 24-5 - Testing Accelerator pedal position sender ........................................................ 24-5 Engine control unit .................................................................................... 24-6 - Operation ............................................................................................... 24-6 - Replacing engine control unit ........................................................................ 24-6 - Coding engine control unit ........................................................................... 24-6 - Adapting the 4AV control unit to the throttle valve control unit -J338- ........................ 24-6 - Adapting EGR valve .................................................................................. 24-6 - Activating and deactivating cruise control system (CCS) ....................................... 24-6 - Learning kickdown operating point ................................................................. 24-6 Testing auxiliary signals ............................................................................. 24-7 - Testing signal from high pressure sender for the air conditioning system -G65- ............ 24-7 - Testing the speed signal ............................................................................. 24-7 - Checking the data BUS .............................................................................. 24-7
28 Ignition System
Ignition System ......................................................................................... 28-1 - General notes on the ignition system .............................................................. 28-1 - Safety measures ...................................................................................... 28-1 - Removing and installing ignition system ........................................................... 28-1 - Inspecting the camshaft position sensor -G163- ................................................. 28-1 page page page page page 1 1 1 2 3
II
Table of Contents
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Octavia 1997
01
01-2
Self-diagnosis II
nections according to the Current Flow Diagram. Only if no fault is detected here should the part be replaced. This applies in particular if faults are shown as sporadic (SP).
If literature appears in the display of the vehicle system tester -V.A.G 1552- look for the text required in the fault
Test wiring and plug connections according to current Testing intake system for leaks (unmetered air)
Chap. 24-2.
Test resistances Chapter 24-1. Test wiring and plug connections according to current
flow diagram.
Test resistances Chapter 24-1. Test wiring and plug connections according to current
flow diagram.
Electrical fault in the circuit Voltage too low Voltage too high Signal too slow No activity Electrical fault in the circuit
Test lambda probe -G130- and lambda control downstream of catalytic converter Chapter 24-4
Self-diagnosis II
01-2 page 1
01
Readout on -V.A.G 155216521 Bank 1, probe 2 16522 Bank 1, probe 2 16524 Bank 1, probe 2 16554 Bank 1, fuel metering system
Octavia 1997
1.6 l/75 kW Engine, Fuel Injection and Ignition System Rectifying fault
Test lambda probe -G130- and lambda control downstream of catalytic converter Chapter 24-4.
Test injection valves Chapter 24-2 Test fuel pump 1.6/75 Engine, Mechanical Components; Rep. Gr. 20
Inspect vacuum lines for leaks Testing intake system for leaks (unmetered air)
Chap. 24-2. 16555 Bank 1, fuel metering system 16556 Bank 1, fuel metering system 16684 Combustion misfiring detected 16685 Cyl. 1 Combustion misfiring detected 16686 Cyl. 2 Combustion misfiring detected 16687 Cyl. 3 Combustion misfiring detected 16688 Cyl. 4 Combustion misfiring detected 16705 Engine speed sender -G28 16706 Engine speed sender -G28 16711 Knock sensor 1 -G61 16712 Knock sensor 1 -G61 Implausible signal No signal System too lean System too rich
Test ignition cables and spark plugs Chap. 28-1. Test power output stage -N122- Chapter 28-1. Read measured value block, display groups 014, 015
and 016 Chap. 01-5.
Test resistance of sender (7301000 ). Test wiring and plug connections according to current
flow diagram.
01-2 page 2
Self-diagnosis II
Octavia 1997
1.6 l/75 kW Engine, Fuel Injection and Ignition System Rectifying fault Malfunction
01
Test resistance of sender (7301000 ). Test wiring and plug connections according to current
flow diagram.
Implausible signal
Test camshaft position sensor -G163- Chap. 28-1. Test wiring and plug connections according to current
flow diagram.
Camshaft position sensor -G163- and camshaft pos. sensor => Sender -G40-are identical.
Readout on -V.A.G 155216788 EGR system control difference Signal too low
Rectifying fault
Adapt EGR valve -N18- Chap. 24-6. Test exhaust gas recirculation system 1.6/75 Engine, Mechanical Components; Rep. Gr. 26 Efficiency too low 16804 Bank 1, catalytic converter system
Generate readiness code Chapter 01-4. Inspect exhaust system for leaks or inspect for damage
if necessary between both lambda probes 1.6/75 Engine, Mechanical Components; Rep. Gr. 26.
Perform emission test Inspection and Maintenance. Test solenoid valve 1 for activated charcoal filter system -N80- with the final control diagnosis Chapter 01-1.
Inspect hoses and connection pipes from fuel tank up Test wiring and plug connections according to current
flow diagram. 16845 Fuel gauge signal Implausible signal
to the throttle valve control unit 1.6/75 Engine - Mechanical Components; Rep. Gr. 20.
Test CAN databus Chap. 24-7. Test dash panel insert Electrical System;
Rep. Gr. 90. 16885 Vehicle speed signal Implausible signal
Test vehicle speed signal Chapter 24-7. Test CAN databus Chap. 24-7. Test dash panel insert Electrical System;
Rep. Gr. 90. 16890 Idling control 16891 Idling control Speed under nominal value Speed above nominal value
Test throttle valve control unit -J338- Chapter 24-5. Testing intake system for leaks (unmetered air)
Chap. 24-2.
Self-diagnosis II
01-2 page 3
01
Readout on -V.A.G 155216916 AC pressure sensor -G65 16917 AC pressure sensor -G65 16935 PAS pressure/switch -F88 16946 Voltage supply
Octavia 1997
1.6 l/75 kW Engine, Fuel Injection and Ignition System Rectifying fault
Test signal from high pressure sensor for air conditionSignal too high Implausible signal Voltage too low ing -G65- Chapter 24-7.
Test CAN databus Chap. 24-7. Read out fault memory of all control units.
01-2 page 4
Self-diagnosis II
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Octavia 1997
01
01-4
Self-diagnosis IV
Readiness code
Operation
The readiness code is an 8-digit numerical code that provides information on the status of the emission-relevant diagnosis. If the diagnosis for a system was successfully performed (e.g. diagnosis of catalytic converter), the relevant position of the numerical code is set from 1 to 0. This diagnosis is performed at regular intervals during normal driving. If repairs have been done on a system relevant for the exhaust gas it is recommended to generate the readiness code as this guarantees that these systems operate according to the specifications. If a fault is detected during diagnosis, it is then stored in the fault memory. The readiness code is erased if the fault memory is erased or if there is an interruption to the voltage supply.
Procedure
Function
with Q .
1 5 enter readiness code and confirm Readiness code 00000000 - Test complete ->
The following readout must appear in the display after successfully completing all the checks:
Press
.
0 6 End output and confirm with Q . Readiness code 00101101 - Test not complete ->
Enter function
Self-diagnosis IV
01-4 page 1
01
Octavia 1997
X 0
X 0
0 0 0 0 0 0
Lambda probes Air conditioning (no diagnosis at present/always 0) Secondary air system Activated charcoal filter (tank vent system) Catalytic converter heater (no diagnosis at present/always 0) Catalytic converter
Test conditions
Vehicle stopped. All electrical components such as lights and rear window heater must be switched off.
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics Chapter 01-1.
The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
Press
01-4 page 2
Self-diagnosis IV
Octavia 1997
01
The readiness code is reset or erased each time the fault memory is erased.
Readout on display: Note
Vehicle system test The fault memory is erased ->
If the ignition is switched off during Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Press
Select function
0 4 initiate basic setting and conInitiating basic setting Enter display group number XXX
try with
Q. System in basic setting 77 700 rpm 1.9 g/s 0.0 % -> Test ON
Press
C.
try with
Q.
Readout on display:
Edition 10.04 S00.5135.52.20
Self-diagnosis IV
01-4 page 3
01
Octavia 1997
After initiating diagnosis of engine control unit the display in field 4 changes from Test OFF to Test ON.
Run engine at idling speed until Syst. O.K. is displayed in display field 4. If the display does not occur as described:
Press
C.
try with
Q. System in basic setting 46 700 rpm 250,0 C 0,96 -> Test OFF
Depress brake pedal and accelerator simultaneously. Engine speed is increased and the readout in display
field 4 switches from Test OFF to Test ON. For engines with engine code AVU
Conduct a test drive at a constant speed. Pay attention to safety precautions for test drives
Chapter 24-1.
Press
C.
01-4 page 4
Self-diagnosis IV
Octavia 1997
01
try with
Continue running engine at higher speed until the catalytic converter temperature in display field 2 shows at least 200 C. Note
Press
C.
try with
Q. System in basic setting 34 700 rpm 300.0 C 0.000 -> Test OFF
Self-diagnosis IV
01-4 page 5
01
Note
Octavia 1997
Press
C.
Work step 8: Diagnosis of activated charcoal filter system (tank vent system)
Readout on display:
Initiating basic setting Enter display group number XXX
try with
Readout on display: After initiating diagnosis of engine control unit the display in field 4 changes from Test OFF to Test ON.
Run engine at idling speed until display field 4 indicates specified value TEV O.K.. If the display does not occur as described:
01-4 page 6
Self-diagnosis IV
Octavia 1997
01
01-5
Self-diagnosis V
Test conditions
Coolant temperature must be at least 80 C. All electrical consumers such as e.g. rear window
heater must be switched off.
Procedure
Display groups 001 up to 028 01-5 page 1. Display groups from 030 Chap. 01-6.
xxxxxxxx 4
Lambda control before catalyst Coolant temperature Engine speed (idling speed)
< Readout on display < Display field Setting condition for basic setting
Self-diagnosis V
Specification 1x111111
-10,010,0 %
01-5 page 1
01
Octavia 1997
Analysis: Display group 001, display field 1 - engine speed (idling speed)
Rectifying fault
Interrogate fault memory Chapter 01-1. Inspecting air intake system for tightness
(unmetered air) Chapter 24-2.
Analysis: Display group 001, display field 3 - lambda control before the catalytic converter
Rectifying fault
not within tolerance Minimum range: Mixture too rich, the lambda control leans the mixture Plus range: Mixture too lean, lambda control enriches Unmetered air Injection valve defective
Analysis: Display group 001, display field 4 - Setting conditions for basic setting
X 1
X x
1 1 1 1 1 1
AC compressor disconnected Idling detected Lambda control: o.k. Throttle valve closed Engine speed less than 2000 rpm Coolant temperature more than 80C
01-5 page 2
Self-diagnosis V
Octavia 1997
01
Display group 002 Basic functions injection time, air mass meter
Engine idling Coolant temperature 80 C x.x g/s 4 < Display field Drawn in air mass Injection period Engine load Engine speed (idling speed) Specification 2,04.5 g/s 2,04.0 ms 15,035,0 % 640900 /rpm Analysis 01-5 page 3 01-5 page 3 01-5 page 7 01-5 page 2 < Readout on display
Rectifying fault
Test solenoid valve 1 for activated charcoal filter system -N80- with the final control diagnosis Chapter 01-1.
flow rate fitted greater than 4.0 ms increased engine load due to electrical consumers (air conditioning system, fog lights etc.)
Test injected quantity Chapter 24-2. Eliminate increased load (AC, fog lights
etc.).
Rectifying fault
intake manifold and air mass meter greater than 4.5 g/s Gear engaged (automatic gearbox)
Engine loaded by auxiliary equipment
Self-diagnosis V
01-5 page 3
01
Octavia 1997
Display group 003 Basic functions air mass meter, throttle valve angle
Engine idling Coolant temperature 80 C xx.x b. TDC 4 < Display field Ignition angle Throttle valve angle Drawn in air mass Engine speed (idling speed) Specification 0,015.0 b. TDC 1,54,0 % 2,04.5 g/s 640900 /rpm Analysis -- 01-5 page 4 01-5 page 3 01-5 page 2 < Readout on display
Rectifying fault
Remove fault.
01-5 page 4
Self-diagnosis V
Octavia 1997
01
Analysis: Display group 004, display field 2 - supply voltage to the engine control unit
Rectifying fault
discharged
Battery heavily loaded just after start by a
control unit Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Rectify any current drain. Test voltage regulator, replace if necessary Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
charger
Rectifying fault
Conduct road test if necessary. Coolant temperature sender or cable con- Test resistances Chapter 24-1.
nection to engine control unit faulty
Radiator dirty Radiator fan not operational Thermostat for map-controlled engine
Test thermostat for map-controlled engine Test resistances Chapter 24-1. Test wiring and plug connections according to current flow diagram.
Test wiring and plug connections to coolant temperature sender -G62- according to current flow diagram.
Rectifying fault
or earth
Test resistances Chapter 24-1. Test wiring and plug connections to intake
air temperature sender -G42- according to current flow diagram.
Self-diagnosis V
01-5 page 5
01
Octavia 1997
01-5 page 6
Self-diagnosis V
Octavia 1997
01
Rectifying fault
throttle driving
Unmetered air
Injector or spark plugs faulty. Switch off electrical consumers. Turn steering wheel into middle position. Move selector lever into position P or
N.
inders)
Electrical consumers on Steering wheel at limit stop Gear engaged (automatic gearbox) Air mass meter faulty
Rectifying fault
Self-diagnosis V
01-5 page 7
01
Display group 011 Ignition angle
Engine idling Coolant temperature 80 C xx.x b. TDC 4
Octavia 1997
2630
---
01-5 page 8
Self-diagnosis V
Octavia 1997
01
Note on display field 3: What is stated is not the specification as the misfiring rate is checked continuously in the engine control unit. If the fault threshold is exceeded, the fault entries are made and the exhaust warning lamp flashes or lights up.
Self-diagnosis V
01-5 page 9
01
Octavia 1997
Rectifying fault
counts up continu- Spark plug defective ously possible mis- Spark plug connector defective firing fault code in Power output stage -N122- faulty fault memory
Injection valve defective
Test power output stage -N122 Check the resistance values of the injector
(12...17 at approx. 20 C).
Test wiring and plug connections to injectors according to current flow diagram. Chap. 24-2.
Unmetered air
Reading measured value block 20 xx.x BTDC 1 xx.x BTDC 2 xx.x BTDC 3
xx.x BTDC 4
Ignition angle relief cylinder 2 through knock control Ignition angle relief cylinder 1 through knock control
01-5 page 10
< Readout on display < Display field Specification Ignition angle relief cylinder 4 through knock control
Self-diagnosis V
Testing intake system for tightness Test exhaust gas recirculation valve -N18with final control diagnosis Chap. 01-1.
0,015.0 b. TDC
0,015.0 b. TDC
0,015.0 b. TDC
0,015.0 b. TDC
Octavia 1997
01
Rectifying fault
ed
Knock sensor incorrectly tightened Component parts on engine loose poor fuel quality
Tighten loosened attached parts. Change grade of fuel. Test wiring and plug connections to knock
sensor -G61- according to current flow diagram.
corroded
Engine damage
Self-diagnosis V
01-5 page 11
01
Octavia 1997
01-5 page 12
Self-diagnosis V
Octavia 1997
01-6
Self-diagnosis VI
no display
Status lambda control downstream of catalytic converter Status lambda control upstream of catalytic converter
Note
The first position in the 3-digit numerical block fluctuates initially between 0 and 1 (lambda probe heater OFF and ON).
Note
regarding display field 2
under load.
Analysis: Display group 030, display field 1 and 2 - status of lambda control
X 1 1 1 X X Meaning
01
Specification
01-6 page 1
01
Display group 031, lambda control - lambda values upstream of catalytic converter
Engine idling Coolant temperature 80 C
no display
no display
Lambda learned value at part load (multiplicative) Lambda learned value at idling speed (additive)
Note
to the display fields 1 and 2:
Low readouts indicate that the engine is running too rich and the lambda control therefore produces a leaner mix-
ture.
High readouts mean that the engine is running too lean and the lambda control therefore produces a richer mixture. add = additive - The effect of the fault (e.g. unmetered air) becomes increasingly less as engine speed rises. In the
case of an additive initialisation value the injection period is changed by a fixed rate. This rate is independent of the basic injection period.
mul = multiplicative - The effect of the fault (e.g. faulty injector) becomes greater as engine speed rises. The mul-
tiplicative learned value is a percentage change in the injection period. This change is dependent on the basic injection period.
01-6 page 2
Octavia 1997 < Readout on display 4 < Display field no display < Readout on display 4 < Display field no display
Self-diagnosis VI
Specification
Analysis ---------
0,99001,0100 0,99001,0100
Specification
-10,010,0 % -14,014,0 %
Octavia 1997
01
Analysis: Display group 032, display field 1 and 2 Lambda learned values
Rectifying fault
learned values under partial load: Oil dilution (higher fuel content in the oil) possible
Injection valve leaks Fuel pressure too high Solenoid valve 1 for activated charcoal fil-
Test solenoid valve 1 for activated charcoal filter system with the final control diagnosis Chapter 01-1.
Test lambda probe -G39- and lambda control upstream of catalytic converter Chapter 24-4.
probe -G39- dirty high lambda initiali- High learned values in idling at less high learned values in partial load: Unmetered sation values air in intake manifold region possible
Unmetered air between air mass meter
Remove fault.
Test injected quantity Chapter 24-2. Display field 1 and 2 high: Air mass meter Test wiring and plug connections to air
faulty mass meter -G70- according to current flow diagram.
gasket
Lambda probe heater faulty or lambda
Test lambda probe -G39- and lambda control upstream of catalytic converter Chapter 24-4.
probe dirty
Self-diagnosis VI
01-6 page 3
01
Display group 033 Lambda control - Lambda probe upstream of catalytic converter
Engine idling Coolant temperature 80 C
no display
Note
Re display field 2:
Analysis: Display group 033, display field 2 - lambda probe voltage upstream of catalytic converter
Display field: 1 constant 0.000...1.400 V or constant 1.600...3.600 V constant 3,600 V constant 0.000 V
01-6 page 4
Octavia 1997 < Readout on display 4 < Display field no display verter Chapter 24-4
Self-diagnosis VI
Specification
1,401,60 V
-10,010,0 %
Rectifying fault
Octavia 1997
01
Display group 034, diagnosis of lambda probe before catalytic converter (ageing test)
Mode basic setting 04 BFQ: Brake and accelerator pedal pressed simultaneously, engine running at fast idling AVU: Brake pedal depressed, engine running at high engine speed System in basic setting 34 xxxx rpm 1 xxx.x C 2 x.xxx 3 Text 4 < Display field Result of test of lambda probe ageing upstream of catalytic converter (Test OFF, Test ON, B1-S1 O.K., B1-S1 not O.K.) Disregard display Catalytic converter temperature Engine speed
1)
Analysis ---
-------
Display group 036 Operational readiness of lambda probe downstream of catalytic converter
Mode basic setting 04 Engine idling System in basic setting 36 x.xx V 1 Text 2 3 4 < Display field no display no display Test lambda probe downstream of catalytic converter (Test OFF, Test ON, B1-S2 O.K., B1 S2 n.o.k.) Lambda probe voltage after catalytic converter B1-S2 O.K. Specification Analysis ------ < Readout on display
0,001,00 V
01-6 page 6
Self-diagnosis VI
01-6 page 5
01
Octavia 1997
Voltage of the 4-pin lambda probe in U in mV A: Lambda probe voltage high rich mixture (fuel surplus or air shortage) high CO value B: Lambda probe voltage low lean mixture (fuel shortage or air surplus) low CO value
Analysis: Display group 036, display field 1 - Voltage of lambda probe, lambda probe downstream of catalytic converter
Rectifying fault
da probe, lambda probe cable, earth lead, engine control unit lambda probe cable, earth lead, engine control unit probe, lambda probe cable, earth lead, engine control unit
constant 0.00 V
Text 4
Heater of lambda probe upstream of catalytic converter (Heating.bC.OFF/heating.bC.ON) Internal resistance of lambda probe upstream of catalytic converter
01-6 page 6
< Readout on display < Display field Heater of lambda probe downstream of catalytic converter (Heating.aC.OFF, heating.aC.ON) ----Self-diagnosis VI
Specification Htg.bC.ON
Analysis ---
-----
Htg.bC.ON
---
Octavia 1997
01
Display group 043, diagnosis of lambda probe after the catalytic converter (ageing test)
Mode basic setting 04 BFQ: Brake and accelerator pedal pressed simultaneously, engine running at fast idling AVU: Brake pedal depressed, engine running at high engine speed System in basic setting 43 xxxx rpm 1 xxx.x C 2 x.xx V 3 Text 4 < Display field Check result of ageing test of lambda probe downstream of catalytic converter (Test OFF, Test ON, B1-S2 O.K., B1-S2 N.O.K.) Lambda probe voltage after catalytic converter Catalytic converter temperature Engine speed
1)
Analysis ---
-------
Analysis ---
-------
Self-diagnosis VI
01-6 page 7
01
Text 4
Operating condition of air conditioning system Engine speed (idling speed - specified value) Engine speed (actual value)
Note
Re display field 2:
What is displayed is the specified engine speed (value computed internally in control unit in line with temperature)
On vehicles not fitted with air conditioning system Compr. OFF is always displayed.
Display group 053 Engine speed increase with increased alternator load
Engine idling Coolant temperature 80 C
xxx.x % 4
Supply voltage of the engine control unit Engine speed (idling speed - specified value) Engine speed (actual value)
Note
Re display field 4:
The readout is dependent on the particular electrical components which are switched on, e.g. rear window heater,
01-6 page 8
Octavia 1997 < Readout on display < Display field Operating state of AC compressor < Readout on display < Display field Alternator load
Self-diagnosis VI
Specification
Specification
0,0100,0 % 12,514,5 V
Octavia 1997
xxx.x % 4
Sender 1 for accelerator pedal position Operating condition (idling, partial load, enrichment, trailing throttle, full load) Engine speed
xxxxx 4
Initialisation value idle stabilizer Idling regulator Engine speed (idling speed)
Note
Re display field 3:
The display shows to what extent the idling stabilizer has disinitialised from the constructively given mean value.
On a new engine the value is in the positive region because of the higher friction, on a run-in engine it is in the negative region.
PAS pressure switch ON (steering wheel at limit stop) no meaning Gear engaged 1) Air conditioning switched on
< Readout on display < Display field Throttle valve angle (potentiometer 1 -G187-) --< Readout on display < Display field Operating conditions xxxxx
Self-diagnosis VI
01
Specification
Analysis ---------
0,0100,0 % 0,0100,0 %
6406500 /rpm
Specification
-10,010,0 % -1020 %
640900 /rpm
01-6 page 9
01
xxxxx 4
Note
Re display field 2:
What is displayed is the specified engine speed (value computed internally in control unit in line with temperature)
Text 4
Adaption status
Throttle valve angle (potentiometer 2 -G188-) Throttle valve angle (potentiometer 1 -G187-)
Note
to display group 060:
The adaptation of the throttle valve control unit occurs with the ignition switched on. The engine control unit is adjusted to the throttle valve control unit by selecting display group 060 under function
04 Basic setting. This adjustment must always be performed if a different throttle valve control unit (or completely different engine) or a different engine control unit has been fitted.
The specifications stated in display fields 1 and 2 are not fully utilised in this process. During adaptation the counter in display field 3 counts up to 9.
01-6 page 10
Octavia 1997 < Readout on display < Display field Operating conditions xxxxx < Readout on display < Display field Adaption status (ADP runs, ADP O.K. or ERROR) ADP o.k. 09
Self-diagnosis VI
Specification -1020 %
Specification
Analysis ---------
100,00,0 % 0,0100,0 %
Octavia 1997
xx.x % 4
Sender 1 for accelerator pedal position -G79Throttle valve angle (potentiometer 2 -G188-) Throttle valve angle (potentiometer 1 -G187-)
Note
to display group 062:
The potentiometer on the throttle valve control unit and of the pedal value sensor are duplicated for safety reasons.
The engine control unit constantly verifies the plausibility of the potentiometers. celerator pedal position -G79-. always be approx. 100 %.
The value of sensor -2 for accelerator pedal position -G185- must always be half of the value of sender 1 for ac The potentiometers of the throttle valve control unit contra-rotate. The value of both potentiometers together must The specifications stated are not fully utilised.
Only on vehicles fitted with automatic gearbox Mode basic setting 04 Ignition on, engine stopped System in basic setting 63 xx.x % 1 xx.x % 2 Text 3
Text 4
Kick-down switch
Sender 2 for accelerator pedal position -G185Sender 1 for accelerator pedal position -G79-
Note
Re display field 4:
If actuated appears in display in the display field 4, depress the accelerator pedal fully and hold it in this position.
< Readout on display < Display field Sender 2 for accelerator pedal position -G185< Readout on display < Display field Operating conditions (ERROR, actuated, ADP runs, ADP O.K.) ADP o.k. Kickdown ----Self-diagnosis VI
01
Analysis ---------
3,097,0 %
Specification
-------
01-6 page 11
01
Octavia 1997
Display group 066 cruise control system (only on vehicles with cruise control system)
Engine idling Reading measured value block 66 xxx km/h 1 xxxx 2 xxx km/h 3 xxxx 4 < Display field CCS switch position Driving speed (nominal), last value stored by the CCS Switch position of brake, clutch and CCS Vehicle speed (actual value) Specification xxxx or 0000xxxx --xxxx or 0000xxxx 0 km/h Analysis 01-6 page 12 -- 01-6 page 12 --< Readout on display
Analysis: Display group 066, display field 2 - switch for brake, clutch and CCS
X 1
X 1
Meaning Brake pedal depressed (brake light switch) Brake pedal depressed (brake switch) Clutch depressed (if automatic gearbox fitted: brake pedal depressed) CCS released
1 1
01-6 page 12
Self-diagnosis VI
Octavia 1997
Display group 070 Diagnosis of activated charcoal filter system (tank vent system)
Mode basic setting 04 Engine idling
Text 4
Idling speed controller variation during TVV diagnosis Lambda controller variation during TVV diagnosis
Note
TVV means solenoid valve 1 for activated charcoal filter system. Diagnosis can only be initiated once each time the engine is started.
Note
Re display field 2:
Lambda regulation - deviation in the negative range: activated charcoal filter full.
Lambda regulation - deviation in the positive range: activated charcoal filter empty.
Text 4
< Readout on display < Display field Result of diagnosis (Test ON, Test OFF, TVV O.K., TVV N.O.K.) TVV o.k. < Readout on display < Display field Adaption status (ADP runs, ADP O.K. or ERROR) ADP o.k.
Self-diagnosis VI
01
Specification
Analysis ---
-8,08,0 %
-------
-10,07,0 %
0,0100,0 %
Specification
Analysis ---
-------
01-6 page 13
01
Note
Octavia 1997
The adaptation of the exhaust gas recirculation valve occurs with the ignition on.
The engine control unit is adapted to the exhaust gas recirculation valve by selecting display group 074 under func-
tion 04 Basic position. This adaption must always be performed if another EGR valve (or completely different engine) or another engine control unit has been installed.
Text 4
BFQ: Brake and accelerator pedal pressed simultaneously, engine running at fast idling AVU: Brake pedal depressed, engine running at high engine speed System in basic setting 77 xxxx rpm 1 2 3 < Readout on display
Text 4
01-6 page 14
< Readout on display < Display field Result of the diagnosis (Test ON / Test OFF / Syst. O.K. / Syst. N.O.K.) Syst. o.k. < Display field Result of the diagnosis (Test ON / Test OFF / Syst. O.K. / Syst. N.O.K., interruption) Syst. o.k. ----Self-diagnosis VI
Specification
Analysis ---
-10,025,0 % 0,0100,0 %
640900 /rpm
Specification
Analysis ---
-------
Octavia 1997
Text 4
Note
Re display field 4:
If the throttle is depressed at approx. 2000 rpm, the status must jump from OFF to ON.
xxxxxxxx 4
Meaning of the digits in the 8-digit numerical block, display field 1 - readiness code
The readiness code is only generated when all display positions are at 0. X 0 0 0 0 0 0 0 0 X X X X X X X Checked system
< Readout on display < Display field Specification ON or OFF Status of intake manifold changeover --< Readout on display < Display field Specification ----Diagnosis status 00000000 Exhaust gas recirculation Lambda probe heater Lambda probes Secondary air system Activated charcoal filter (tank vent system) Catalytic converter
Self-diagnosis VI
01
80,0115.0 C
01-6 page 15
01
Octavia 1997
Text 4
01-6 page 16
Self-diagnosis VI
Octavia 1997
Text 4
Note
unit unit
< Readout on display < Display field Status airbag Airbag 1 Combi 1 ABS 1 < Readout on display 4 < Display field ----Airbag 1 ----Possible cause of fault
Self-diagnosis VI
01
Specification
Gearbox 11)
Specification
Rectifying fault
01-6 page 17
01
Text 4
Note
to the display fields 1 and 2:
The coolant temperature at engine outlet must always be higher than at radiator outlet.
xxx.x % 4
Coolant temperature at engine outlet (specified temperature) Coolant temperature at engine outlet (specified temperature)
Note
to the display fields 1 and 3:
The coolant temperature at engine outlet must always be higher than at radiator outlet.
01-6 page 18
Octavia 1997 < Readout on display < Display field Result of the diagnosis (Test ON, Test OFF, Syst. O.K., Syst. N.O.K.) Syst. o.k. 0100 % 0100 C < Readout on display < Display field On/off ratio of thermostat
Self-diagnosis VI
Specification
Analysis ---
-------
80115 C
Specification
Analysis ---------
0,0100,0 %
0,0100,0 C 0,0115.0 C
80,0115.0 C
Octavia 1997
Text 4
Temperature difference engine and radiator outlet Coolant temperature at radiator outlet (specified temperature)
1)
Checked system
Regulator variation: 0 > spec. temp., 1 < act. temp. Fan actuation active Fault present Thermostat actuation active
Note
to bit 1 and 2:
The fan stages may also be actuated by the air conditioning system.
< Readout on display < Display field Status of coolant regulation xxxxxx 0,24.8 V 0110 C --Self-diagnosis VI
01
Specification
1)
01-6 page 19
01
Octavia 1997
01-6 page 20
Self-diagnosis VI
Octavia 1997
24
Safety measures
Caution!
The fuel system is under pressure! Place a cloth around the connecting point before releasing hose connections or when opening the system. Then reduce the pressure by carefully removing the hose or cap.
Observe the following points to prevent injury to persons and/or damage to the injection and preheating system:
Do not touch or remove ignition leads with the engine
fore disconnecting and re-connecting cables of the fuel injection and ignition system as well as of test equipment.
To operate the engine at start speed without it starting
(e.g. for a testing compression pressure), unplug connectors from the ignition unit and connectors from the injectors. After performing the work interrogate fault memory and erase.
Do not carry out engine wash unless the ignition is
switched off.
Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV control unit. If test and measuring devices are required during test drives observe the following:
Always secure the test and measuring devices on the
rear seat and have a second person operate them there. If the test and measuring equipment is operated from the front passenger seat, this can result in injuries to the persons sitting on that seat in the event of an accident which involves the front passenger airbag being deployed.
Rules of cleanliness
Pay careful attention to the following rules of cleanliness when working on the fuel supply or fuel injection systems:
Thoroughly clean the connection points and their sur-
24-1 page 1
24
Octavia 1997
their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. in tool boxes etc.).
When the system is open: avoid working with com-
1 - Activated charcoal filter system solenoid valve 1 -N80-*/** K resistance: 2230 2 - Return-flow line K secure with spring strap clamps K to fuel delivery unit in fuel tank 3 - Feed line K secure with spring strap clamps K from fuel filter 4 - Camshaft position sensor -G163-* K for engines with engine code AVU K under top toothed belt guard K inspect Chapter 28-1 5 - Variable intake manifold changeover valve -N156- */** K inspect Chapter 24-3 6 - Top part of intake manifold K disassembling and assem30 bling 24-1 page 8 7 - Bottom part of intake manifold 8 - Connector, 81 pin K only insert or remove plug when the ignition is switched off K unlock before removing 9 - Engine control unit* K Fitting location: in plenum chamber K replacing Chapter 24-6 10 - Connector, 40 pin K only insert or remove plug when the ignition is switched off K unlock before removing 11 - Throttle valve control unit -J338-* K inspect Chapter 24-5 K 6-pin connector
C B
A D
24-1 page 2
Octavia 1997
24
12 -
13 -
14 15 -
16 -
17 -
18 -
19 20 -
21 22 -
23 24 25 26 -
27 -
K contacts gold-plated Camshaft position sensor -G163-* K for engines with engine code BFQ K at rear of cylinder head K inspect Chapter 28-1 EGR valve -N18- */** K with EGR potentiometer -G212K 6-pin connector K Adaptation Chap. 24-6 Combination valve K Secondary air pump 1.6 l/75 kW Engine, Mechanical Components; Rep. Gr. 26 Protective housing for relays and fuses K installation position: Secondary air injection pump relay -J299- */** Power supply of Simos engine control unit -J363K only on vehicles fitted with automatic gearbox Fuse for brake vacuum pump -V192 Fuse for secondary air injection pump motor -V101coolant temperature sender -G62-* K green K for engine control unit K with coolant temperature sender -G2K resistances 24-1 page 10 Brake vacuum pump -V192- with brake servo unit control unit -J542- (only on vehicles fitted with automatic gearbox) */** K inspect Chapter 24-2 Air mass meter -G70- with intake air temperature sender -G42- * K contacts of sender and of connector gold-plated K resistances for intake air temperature sender -G42- 24-1 page 9 Air filter K disassembling and assembling 24-1 page 9 Power output stage -N122- with ignition coil -N, N128K with identification for ignition leads, do not switch K resistances Chapter 28-1 Engine speed sender -G28-* K resistance: 7301000 Injection valves -N30N33-* K resistance: 1217 (at about 20 C) K test injected quantity, leak tightness and spray pattern of injectors Chapter 24-2. Secondary air injection pump motor -V101- */** K Secondary air system: 1.6 l/75 kW Engine - Mechanical Components; Rep. Gr. 26 Knock sensor I -G61-* K contacts of sender and of connector gold-plated Fuel pressure regulator K inspect Chapter 24-2 4-pin connector K Brown K for lambda probe heater -Z29- and lambda probe downstream of catalytic converter -G130K on underside of vehicle on right Lambda probe downstream of catalytic converter -G130-, 50 Nm* K only coat thread with hot screw paste G 052 112 A3; the paste must not get into the slot of the probe body. K Test lambda probe -G130- and lambda control downstream of catalytic converter Chapter 24-4
24-1 page 3
24
Octavia 1997
28 - 6-pin connector K black K for lambda probe heater -Z19- and lambda probe upstream of catalytic converter -G39K on underside of vehicle on right 29 - Lambda probe upstream of catalytic converter -G39 -, 50 Nm* K Fitting location: in the exhaust manifold K only coat thread with hot screw paste G 052 112 A3; the paste must not get into the slot of the probe body. K Test lambda probe -G39- and lambda control upstream of catalytic converter Chapter 24-4 30 - PAS pressure switch -F88- *
Fig. 1:
1 - Clutch pedal switch -F362 - Brake light switch -F- and Brake pedal switch -F473 - Accelerator pedal position sender -G79- and accelerator pedal position sender 2 -G185-
3 2
1
S24-0459
24-1 page 4
Octavia 1997
24
24-1 page 5
24
17 18 -
Octavia 1997
19 20 21 -
22 -
23 24 25 26 27 28 29 30 -
31 32 33 -
34 -
35 36 -
37 38 39 -
40 41 -
K for injection valve -N30...N33Gasket ring Connector K black, 2 pin K for variable intake manifold changeover valve -N156Cable rail Body-bound rivet Top part of intake manifold K with variable intake manifold changeover K disassembling and assembling 24-1 page 8 3-pin plug connection K grey K for engine speed sender K Fitting location: close to dipstick Engine speed sender -G28-* K Resistance 730...1000 Support K between intake manifold and cylinder head 8 Nm K for attaching vent connection Rubber bush 8 Nm To activated charcoal filter solenoid valve 1 -N80K Activated charcoal filter 1.6 l/75 kW Engine, Mechanical Components; Rep. Gr. 20 From heater feed Connector K 6-pin K contacts gold-plated K for throttle valve control unit -J338To T-connection and on to coolant expansion bottle 10 Nm K for engines with engine code BFQ Camshaft position sensor -G163K for engines with engine code BFQ K inspect Chapter 28-1 Connector K for engines with engine code BFQ K 3-pin K for camshaft position sensor -G163To the brake servo unit Gasket ring K for engines with engine code BFQ K replace if damaged K before fitting moisten with clean engine oil Gasket K replace From exhaust gas recirculation valve Air intake hose K with crankcase ventilation valve K with crankcase ventilation with heating resistor (only for models with optional equipment) For housing ventilation To EGR valve -N18K clean air connection to fresh air supply
Fuel Injection System Edition 10.04 S00.5135.52.20
24-1 page 6
Octavia 1997
24
42 - To secondary air pump 43 - Air mass meter -G70- with intake air temperature sender -G42- * K contacts of sender and of connector gold-plated K resistances for intake air temperature sender -G42- 24-1 page 9
S24-0469
24-1 page 7
24
Octavia 1997
1 - 8 Nm 2 - Throttle valve control unit -J338-* K 6-pin connector K contacts gold-plated K inspect Chapter 24-5 K if replaced adapt engine control unit Chapter 24-6 K if replaced, adapt automatic gearbox control unit Automatic Gearbox; Rep. Gr. 01 3 - Gasket ring K replace 4 - Pressure relief valve K protects intake manifold from damage if excess pressure exists 5 - Top part of intake manifold 6 - Body-bound rivet 7 - Variable intake manifold changeover valve -N156- */** K inspect Chapter 24-3
24-1 page 8
Octavia 1997
24
Resistances for intake air temperature sender -G42The nominal value in field -A- applies for temperature range 0...50 C, nominal value in field -B- applies for temperature range 50...100 C. Read out examples:
30 C is within the range -A- and equals a resistance
of 1.5...2.0 k.
80 C is in range -B- and corresponds to a resistance
of 275...375 .
24-1 page 9
24
Octavia 1997
Check resistance values of the intake manifold temperature sender -G42- between contacts 2 + 4.
Resistances for the coolant temperature sender -G62The nominal value in field -A- applies for temperature range 0...50 C, nominal value in field -B- applies for temperature range 50...100 C.
of 1500...2000 k.
80 C is in range -B- and corresponds to a resistance
of 275...375 .
24-1 page 10
Octavia 1997
24
24-2
Testing components
Test wiring and components with Test box -V.A.G 1598/31The test box -V.A.G 1598/31- is designed in such a way that it can be simultaneously connected to the wiring loom of the engine control unit and to the actual engine control unit. The advantage being that the electronic engine control remains fully operational with the test box connected (e.g. measuring signals while the engine is running). Whether the control unit is additionally connected to the test box or not, is indicated in the particular test procedure. Always use the measuring tool set -V.A.G 1594 A, B oder C- to connect the measuring tools (e.g. handheld multimeter -V.A.G 1715- etc.). The contact numbers of the connector of the control unit and the socket numbers of the test box -V.A.G 1598/31are identical. Special tools, test and measuring equipment and auxiliary items required
Test box -V.A.G 1598/31-
WARNING!
To avoid damaging the electronic components, switch on the relevant measuring range before connecting the measuring cables and comply with the test conditions.
Remove wiper arm Electrical System; Rep. Gr. 92. Remove the cooling water tank cover Body Work;
Rep. Gr. 66.
It is therefore necessary to interrogate the fault memory after reconnecting the engine control unit, and if necessary erase Chapter 01-1.
Testing components
24-2 page 1
24
Octavia 1997
Inspecting the injection rate, tightness and jet formation of the injectors
Special tools, test and measuring equipment and auxiliary items required
Hand multimeter (e.g. -V.A.G 1348/2B-) Digital potentiometer (e.g. -V.A.G 1630-)
Test condition
tors Chapter 24-1. The fuel hoses remain connected. perature sender -G62- -2-.
Unplug the 4-pin connector -1- from the coolant tem Set digital potentiometer -V.A.G 1630- side A to 15 k
and connect to the unplugged connector contact 3 and 4 using auxiliary cables.
24-2 page 2
Testing components
Octavia 1997
24
Hold the injectors in the measuring glasses. Operate starter (2nd person required). The injectors
must spray in a pulsing action in line with firing order.
When testing the injection rate also check the jet formation. The jet must be the same for all valves.
Insert injector to be tested in a measuring glass. Connect one contact of injector to the battery earth. Connect the second contact of the injector to the remote control.
Actuate the remote control for 30 seconds. Perform the measurement on all injectors. Once all four injectors have been driven, position the
graduated measuring glasses on an even base. Nominal value per injection valve: 87...95 ml.
If the measured value of one or more injectors is outside the tolerance value, disconnect the fuel pump and replace the defective injector (or defective injectors) Chapter 24-1. The injectors are installed in the reverse order. Pay attention to the following:
Replace the O-rings and all the injectors and moisten
onto the cylinder head and and screw up at the same time Chapter 24-1.
Testing components
24-2 page 3
24
Octavia 1997
Test sequence
WARNING!
The fuel system is under pressure! Before opening the system lay cleaning cloths around the connection point. Reduce pressure by carefully releasing the connection point.
Disconnect the connection of the fuel supply hose -1(black or black marking) and catch fuel leaking out with cloth.
Plug fuse no. 28 (fuel delivery unit) into the fuse holder.
Test flow rate of fuel delivery unit 1.6 l/75 kW Engine, Mechanical Components; Rep. Gr. 20. If the specified value is reached:
Switch off ignition. Test for leaks and holding pressure. Observe pressure drop at gauge. A pressure of at least 0.2 MPa (2.0 bar) must be indicated on the gauge after 10 minutes. If the holding pressure drops below 0.2 MPa (2.0 bar):
24-2 page 4
Testing components
Octavia 1997
24
Start engine and run in idle. After the pressure has been built up, switch ignition
off. Simultaneously connect the shut-off cock -arrowto the pressure gauge appliance .
Inspect pressure measuring device for leaks. Inspect connections, O-rings on the fuel rail and injectors for leaks. If no leaks are found:
Before removing the pressure measuring device, place the cloth around the line connection and remove the fuse no. 28 (fuel delivery unit) from the fuse holder.
Test condition
search spray is sucked in with the unmetered air. The leak search spray reduces the ignition performance of the mixture. This results in a drop in engine speed and a change in the lambda probe control value.
You must comply with the safety instructions on the
box.
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
Testing components
24-2 page 5
24
Octavia 1997
Press Enter
with Q .
.
0 6 for the function End output and confirm
Switch off ignition. Check the sprayed location of the intake system for
leaks and if necessary eliminate the fault.
Testing brake vacuum pump -V192The brake servo assistance system on vehicles fitted with automatic gearbox improves provision of the vacuum required. The brake vacuum pump -V192- and the brake servo assistance control unit -J542- form a single unit. Special tools, test and measuring equipment and auxiliary items required
Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C Hand multimeter (e.g. -V.A.G 1715-) Diode test lamp (e.g. -V.A.G 1527B-) Adapter cable set (e.g. -V.A.G 1594 A, B oder C-) Test box -V.A.G 1598/31-
24-2 page 7 and cables Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Test control
Unplug plug -1- from the vacuum pump -2-. Connect diode test lamp to contacts 1 and 2 of the
plug -1-.
Switch on the ignition and initate an actuator diagnosis. The LED must flash. The LED flashes:
24-2 page 6
Testing components
Octavia 1997
24
1 2
Switch off ignition. Check fuse -3- for the vacuum pump.
If fuse is o.k.:
Test wiring.
S24-0465
Connect multimeter for voltage measurement (terminal 30) to contacts 1 and 5. Specified value: approx. battery voltage
Switch on ignition.
Specified value: approx. battery voltage If the specified values are reached:
Testing components
24-2 page 7
24
Octavia 1997
24-2 page 8
Testing components
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Octavia 1997
28
28 Ignition System
28-1 Ignition System
sis system.
A minimum voltage of 11.5 V is required for perfect
tect and store a fault. It is therefore necessary to interrogate the fault memory after having completed all inspections and repairs, and if necessary delete.
If after fault finding, repair or inspection of compo-
nents the engine starts briefly and then stops, it is possible that the immobiliser blocks the 4AV control unit. In this case the fault memory must be interrogated and if necessary the control unit must be adapted.
Safety measures
Observe the following points to prevent injury to persons and/or damage to the injection and preheating system:
Do not touch or remove ignition leads with the engine
heating system and measuring device wires when the ignition is switched off.
To operate the engine at start speed without it starting
(e.g. for a testing compression pressure), unplug connectors from the ignition unit and connectors from the injectors. After performing the work interrogate fault memory and erase.
Do not carry out engine wash unless the ignition is
switched off.
Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV control unit.
If the engine must be operated at start speed without
Ignition System
28-1 page 1
28
Octavia 1997
A D
28-1 page 2
Ignition System
Octavia 1997
28
15 - 10 Nm K for engines with engine code BFQ 16 - Camshaft position sensor -G163K for engines with engine code BFQ K check 28-1 page 3 17 - Gasket ring K for engines with engine code BFQ K replace if damaged K before fitting moisten with clean engine oil 18 - Rotor K for engines with engine code BFQ K on the camshaft
Inspecting the camshaft position sensor -G163The camshaft position sensor -G163- indicates the ignition position for cylinder 1. If it fails the knock control is deactivated and the ignition angle is slightly reduced as a cylinder assignment is no longer possible. Without sensor signal the engine runs on and can be started again:
In the event of a fault detection the engine control unit
a displacement of an engine revolution. Instead of occurring with the injection valve open the injection occurs "pre-engaged" (before the closed injection valve). This only has a very slight influence on the quality of the mixture formation. Note
The camshaft position sensor -G163- is identical to
Special tools, test and measuring equipment and auxiliary items required
Hand multimeter (e.g. -V.A.G 1715-) Adapter cable set (e.g. -V.A.G 1594 A, B oder C-) Test box -V.A.G 1598/31-
Ignition System
28-1 page 3
28
Test sequence
Octavia 1997
For engines with engine code AVU Continued for all engines
28-1 page 4
Ignition System
Octavia 1997
28
For engines with engine code AVU 3-pin plug -1- on wiring loom, contact 1+3 If the specified value is not reached: Specification min. 4,5 V
1 2 3
1 2
S28-0124
Ignition System
28-1 page 5
28
Octavia 1997
28-1 page 6
Ignition System