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Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

List of Supplements to Workshop Manual

Octavia 1997
1.6 l/75 kW Engine, Fuel Injection and Ignition System
Edition 06.01
Supplement 1 2

Edition 06.01 08.02 10.04

Subject Basic Edition Changes for engine BFQ Modifications in Rep. Gr. 01 24 and 28

Article Number S00.5135.50.20 S00.5135.51.20 S00.5135.52.20

Edition 10.04 S00.5135.52.20

List of Supplements

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

List of Supplements

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

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

24 Fuel Formation, Injection


Fuel Injection System ................................................................................. 24-1 - Safety measures ....................................................................................... 24-1 - Rules of cleanliness ................................................................................... 24-1 - Overview of fitting locations .......................................................................... 24-1 - General notes on the injection system ............................................................. 24-1 - Removing and installing parts of the injection system ........................................... 24-1 - Disassembling and assembling fuel distributor with injectors .................................. 24-1 - Disassembling and assembling top part of intake manifold ..................................... 24-1 - Disassembling and assembling the air filter ....................................................... 24-1 - Resistances for intake air temperature sender -G42- ........................................... 24-1 - Resistances for the coolant temperature sender -G62- ......................................... 24-1 Testing components ................................................................................... 24-2 - Test wiring and components with Test box -V.A.G 1598/31- ................................... 24-2 - Inspecting the injection rate, tightness and jet formation of the injectors ..................... 24-2 - Test fuel pressure regulator and holding pressure ............................................... 24-2 - Testing the intake system for tightness (unmetered air) ........................................ 24-2 - Testing brake vacuum pump -V192- ............................................................... 24-2 Inspecting functions ................................................................................... 24-3 - Testing idling speed ................................................................................... 24-3 - Testing the intake manifold changeover ........................................................... 24-3 Lambda control ......................................................................................... 24-4 - Testing lambda probe -G39- and lambda control upstream of catalytic converter .......... 24-4 page page page page page page page page page page page page page page page page page page page page page 1 1 1 2 4 5 7 8 9 9 1 1 2 4 5 6 1 1 2 1 1

page 10

Edition 10.04 S00.5135.52.20

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

Edition 10.04 S00.5135.52.20

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Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

01

01-2

Self-diagnosis II

Fault codes 16486 16990


Note
The fault table is arranged according to the 5-digit fault code on the left. The SAE code which is displayed on the right next to the fault code (e.g.. P0107) can be ignored (at present only

valid for USA).


Explanations regarding fault types (e.g. open circuit or short-circuit to earth) Operating instructions for the ve-

hicle system tester.


If parts are output as faulty: First check all cables and connectors to these components as well as the earth con-

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

table under the fault code.


Readout on -V.A.G 155216486 Air mass meter -G70 16487 Air mass meter -G70 Signal too low Signal too high Rectifying fault

Read measured value block, display group 002, display


field 4 Chap. 01-5. flow diagram.

Test wiring and plug connections according to current Testing intake system for leaks (unmetered air)
Chap. 24-2.

Replace air filter if necessary Chap. 24-1.


16496 Signal too low Intake air temperature sender G42 16497 Signal too high Intake air temperature sender G42 16500 Coolant temperature sender G62 16501 Coolant temperature sender G62 16502 Coolant temperature sender G62 16514 Bank 1, probe 1 16515 Bank 1, probe 1 16516 Bank 1, probe 1 16517 Bank 1, probe 1 16518 Bank 1, probe 1 16520 Bank 1, probe 2 Implausible signal

Read measured value block, display group 004, display


field 4 Chap. 01-5.

Test resistances Chapter 24-1. Test wiring and plug connections according to current
flow diagram.

Read measured value block, display group 004, display


Signal too low field 3 Chap. 01-5.

Signal too high

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 -G39- and lambda control upstream


of catalytic converter Chapter 24-4.

Test lambda probe -G130- and lambda control downstream of catalytic converter Chapter 24-4

Edition 10.04 S00.5135.52.20

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

Voltage too low Voltage too high No activity Malfunction

Test lambda probe -G130- and lambda control downstream of catalytic converter Chapter 24-4.

Test fuel pressure regulator and holding pressure


Chap. 24-2

Test injection valves Chapter 24-2 Test fuel pump 1.6/75 Engine, Mechanical Components; Rep. Gr. 20

Inspect exhaust system for leaks 1.6/75 kW Engine,


Mechanical Components; Rep. Gr. 26

Inspect secondary air system for leaks 1.6/75 kW


Engine, Mechanical Components; Rep. Gr. 26

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 lambda probe -G39- and lambda control upstream


of catalytic converter Chapter 24-4.

Test fuel pressure regulator and holding pressure


Chap. 24-2

Check the resistance values of the injectors (12...17


at approx. 20 C).

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.

Replace engine speed sender -G28-.


Signal too low

Read measured value block, display groups 020, 026


Signal too high and 028 Chap. 01-5.

01-2 page 2

Self-diagnosis II

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System Rectifying fault Malfunction

01

Readout on -V.A.G 155216719 Engine speed sender -G28

Test resistance of sender (7301000 ). Test wiring and plug connections according to current
flow diagram.

Replace engine speed sender -G28-.


16725 Camshaft pos. sensor => Sender G40 1) 16726 Camshaft pos. sensor => Sender G40 1)
1)

Implausible signal

Read measured value block; display group 012; check


values in display fields 3 and 4 Chapter 01-5.

Signal too low

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

Test exhaust gas recirculation valve -N18- with final


control diagnosis Chap. 01-1.

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.

16825 Tank ventilation system

Flow rate incorrect

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 fuel gauge sender -G- Electrical System;


Rep. Gr. 90.

Test CAN databus Chap. 24-7. Test dash panel insert Electrical System;
Rep. Gr. 90. 16885 Vehicle speed signal Implausible signal

Reading measured value block, display group 005,


checking values in display field 3 Chap. 01-5.

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.

Adapt throttle valve control unit Chapter 24-6.

Edition 10.04 S00.5135.52.20

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

Signal too low

Test signal from high pressure sensor for air conditionSignal too high Implausible signal Voltage too low ing -G65- Chapter 24-7.

Read measured value block, display group 055, check


readouts in display field 4 Chapter 01-6.

Test voltage supply of engine control unit Current


Flow Diagrams, Electrical Fault Finding and Fitting Locations

Test battery and alternator Electrical System;


Rep. Gr. 27 16955 Brake light switch -F Implausible signal

Read measured value block, display group 066


Chapter 01-6. flow diagram.

Test wiring and plug connections according to current


16984 Databus drive 16985 Control unit defective 16988 Control unit defective 16990 Control unit defective missing message

Test CAN databus Chap. 24-7. Read out fault memory of all control units.

Replace engine control unit Chapter 24-6.

01-2 page 4

Self-diagnosis II

Edition 10.04 S00.5135.52.20

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Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

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.

Reading readiness code


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-

Procedure

Connect vehicle system tester -V.A.G 1552-. Switch


ignition on and select address word 01 Engine electronics Chap. 01-1.

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

Read-out on display: Not all checks were performed successfully.

Press . Generate readiness code 01-4 page 2.

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Self-diagnosis IV

01-4 page 1

01

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Meaning of the 8-digit numerical block of the readiness code

X 0

X 0

Checked system Exhaust gas recirculation Lambda probe heater

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

Generating readiness code


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-

Test conditions

Vehicle stopped. All electrical components such as lights and rear window heater must be switched off.

On vehicles with an automatic gearbox the selector lever must be in position P or N.

The coolant temperature must be at least 80C


display group 004, display field 3. display group 004, display field 4.

The intake air temperature must be below 60 C

Procedure

Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics Chapter 01-1.

Work step 1: Interrogating fault memory

Enter address word


and confirm with Q .

0 2 Interrogate fault memory X faults detected

The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:

Rectify the faults by referring to the fault table


Chapter 01-2 and 01-3. If no fault is stored:

Press

01-4 page 2

Self-diagnosis IV

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

01

Work step 2: Erasing fault memory

Enter address word


confirm with Q . Note

0 5 Erase fault memory and

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

Work step 3: Diagnosis of secondary air injection system

Select function

0 4 initiate basic setting and conInitiating basic setting Enter display group number XXX

firm entry with Q . Readout on display:

0 7 7 for the indicator group 077 and confirm en-

try with

Q. System in basic setting 77 700 rpm 1.9 g/s 0.0 % -> Test ON

Readout on display: For engines with engine code BFQ

Depress brake pedal and accelerator simultaneously.


For engines with engine code AVU

Depress brake pedal and hold pressed.


Continued for all engines Engine speed is increased and the readout in display field 4 switches from Test OFF to Test ON.

Run engine at high speed until specified value Syst.


O.K. appears If the display does not occur as described:

Interrogate fault memory Chapter 01-1.


If the display occurs as described:

Press

C.

Work step 4: Diagnosis of exhaust gas recirculation system


Readout on display:
Initiating basic setting Enter display group number XXX

0 7 5 for the indicator group 075 and confirm en-

try with

Q.

Readout on display:
Edition 10.04 S00.5135.52.20

System in basic setting 75 700 rpm 18.4 % -2.3 %

-> System O.K.

Self-diagnosis IV

01-4 page 3

01

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

After initiating diagnosis of engine control unit the display in field 4 changes from Test OFF to Test ON.

Run engine at idling speed until Syst. O.K. is displayed in display field 4. If the display does not occur as described:

Interrogate fault memory Chapter 01-1.


If the display occurs as described:

Press

C.

Work step 5: Catalyst diagnosis


Readout on display:
Initiating basic setting Enter display group number XXX

0 4 6 for the indicator group 046 and confirm en-

try with

Q. System in basic setting 46 700 rpm 250,0 C 0,96 -> Test OFF

Readout on display: For engines with engine code BFQ

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

Set speed to 2500...4500 rpm. The readout in display


field 4 changes from Test OFF to Test ON. Continued for all engines

Catalytic converter temperature in display field 2 must


be at least 400 C. Note

This may take a few mlnutes.

Maintain the speed until the readout in display field 4


shows the specified value CatB1 O.K.. If the display does not occur as described:

Interrogate fault memory Chapter 01-1.


No fault in the fault memory:

Conduct a test drive at a constant speed. Pay attention to safety precautions for test drives
Chapter 24-1.

Once again perform (test of conversion) diagnosis of


catalytic converter. In case of equal result:

Replace catalytic converter 1.6 l/75 kW Engine,


Mechanical Components; Rep. Gr. 26. If the display occurs as described:

Press

C.

01-4 page 4

Self-diagnosis IV

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

01

Work step 6: Diagnosis of lambda probe after catalyst (ageing test)

0 4 3 for the indicator group 043 and confirm en-

try with

Q. System in basic setting 43 700/min 200.0 C 0.85 V -> Test OFF

Readout on display: For engines with engine code BFQ

Depress brake pedal and accelerator simultaneously.


For engines with engine code AVU

Depress brake pedal and hold pressed.


Continued for all engines Engine speed is increased and the readout in display field 4 switches from Test OFF to Test ON.

Continue running engine at higher speed until the catalytic converter temperature in display field 2 shows at least 200 C. Note

This may take a few mlnutes.

Run engine at high speed until display field 4 indicates


specified value B1-S2 O.K.. If the display does not occur as described:

Interrogate fault memory Chapter 01-1.


If the display occurs as described:

Press

C.

Work step 7: Diagnosis of lambda probe before catalyst (ageing test)


Readout on display:
Initiating basic setting Enter display group number XXX

0 3 4 for the indicator group 034 and confirm en-

try with

Q. System in basic setting 34 700 rpm 300.0 C 0.000 -> Test OFF

Readout on display: For engines with engine code BFQ

Depress brake pedal and accelerator simultaneously.


For engines with engine code AVU

Depress brake pedal and hold pressed.


Continued for all engines Engine speed is increased and the readout in display field 4 switches from Test OFF to Test ON.

Catalytic converter temperature in display field 2 must


be at least 350 C.

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Self-diagnosis IV

01-4 page 5

01
Note

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

This may take a few mlnutes.

Run engine at high speed until display field 4 indicates


specified value B1-S1 O.K.. If the display does not occur as described:

Interrogate fault memory Chapter 01-1.


If the display occurs as described:

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

0 7 0 for the indicator group 070 and confirm en-

try with

Q. System in basic setting 70 4.3 % 10.9 % -1.1 % -> Test OFF

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:

Interrogate fault memory Chapter 01-1.


If the display occurs as described:

Press . Read out readiness code 01-4 page 1.

01-4 page 6

Self-diagnosis IV

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

01

01-5

Self-diagnosis V

Reading measured value block


Special tools, test and measuring equipment and auxiliary items required
Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-

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

Connect vehicle system tester - V.A.G 1552-. Start


engine and select address word 01 Engine electronics Chapter 01-1. Readout on display:
Vehicle system test Select function XX 0 8 Read measured value Reading measured value block Enter display group number XXX HELP

Enter address word


Readout on display:

block and confirm the entry with key Q .

Select desired display group:

Display groups 001 up to 028 01-5 page 1. Display groups from 030 Chap. 01-6.

Display groups 001 up to 028

Display group 001 - Basic functions setting conditions


Engine idling Coolant temperature 80 C

Reading measured value block 1 xxx rpm 1 xxx.x C 2 xx.x % 3

xxxxxxxx 4

Lambda control before catalyst Coolant temperature Engine speed (idling speed)

Edition 10.04 S00.5135.52.20

< Readout on display < Display field Setting condition for basic setting
Self-diagnosis V

Specification 1x111111

Analysis 01-5 page 2 01-5 page 2 01-5 page 5 01-5 page 2

-10,010,0 %

80,0115.0 C 640900 /rpm

01-5 page 1

01

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Analysis: Display group 001, display field 1 - engine speed (idling speed)

Display -V.A.G 1552less than 640 rpm

Possible cause of fault


Throttle valve control unit jams/defective

Rectifying fault

Test throttle valve control unit Chapter


24-5.

inspecting idling speed Chapter 24-3.


greater than 900 rpm
Idling not detected Large quantity of unmetered air between

intake manifold and air mass meter


Throttle valve control unit jams/defective

Interrogate fault memory Chapter 01-1. Inspecting air intake system for tightness
(unmetered air) Chapter 24-2.

Test throttle valve control unit Chapter


24-5.

inspecting idling speed Chapter 24-3.

Analysis: Display group 001, display field 3 - lambda control before the catalytic converter

Display -V.A.G 1552 -

Possible cause of fault

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

wait 30 seconds until the display has stabilised

Testing intake system for tightness


Chap. 24-2.

Check the resistance values of the injectors (12...17 at approx. 20 C).

Test wiring and plug connections according to current flow diagram.

Analysis: Display group 001, display field 4 - Setting conditions for basic setting

X 1

X x

Meaning No fault detected by the self-diagnostic function Disregard display

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

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Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

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

Reading measured value block 2 xxx rpm 1 xxx.x % 2 x.x ms 3

Analysis: Display group 002, display field 3 - injection time

Display -V.A.G 1552 less than 2.0 ms

Possible cause of fault


high fuel volume from the activated char-

Rectifying fault

Test solenoid valve 1 for activated charcoal filter system -N80- with the final control diagnosis Chapter 01-1.

coal filter system


incorrect injection valve with too great

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.).

Analysis: Display group 002, display field 4 - inducted air mass

Display -V.A.G 1552 less than 2.0 g/s

Possible cause of fault


Large quantity of unmetered air between

Rectifying fault

intake manifold and air mass meter greater than 4.5 g/s Gear engaged (automatic gearbox)
Engine loaded by auxiliary equipment

Eliminate unmetered air. Move selector lever into position P or


N.

Eliminate load (AC, power steering etc.).

Edition 10.04 S00.5135.52.20

Self-diagnosis V

01-5 page 3

01

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Display group 003 Basic functions air mass meter, throttle valve angle
Engine idling Coolant temperature 80 C 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

Reading measured value block 3 xxx rpm 1 x.xx g/s 2 x.x % 3

Analysis: Display group 003, display field 3 - throttle valve angle

Display -V.A.G 1552 greater than 4.0 %

Possible cause of fault


Engine control unit not adapted to throttle

Rectifying fault

Adapt engine control unit to throttle valve


control unit Chapter 24-6.

valve control unit


Throttle valve potentiometer in throttle

Test throttle valve control unit Chapter


24-5.

valve control unit faulty


Throttle valve jams

Remove fault.

Display group 004 Basic functions temperature


Engine idling Coolant temperature 80 C xxx.x C 4 < Display field Intake manifold temperature Coolant temperature Supply voltage of the engine control unit Engine speed (idling speed) Specification -38,080,0 C 80,0115.0 C 12,514,5 V 640900 /rpm Analysis 01-5 page 5 01-5 page 5 01-5 page 5 01-5 page 2 < Readout on display

Reading measured value block 4 xxx rpm 1 xx.x V 2 xxx.x C 3

01-5 page 4

Self-diagnosis V

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

01

Analysis: Display group 004, display field 2 - supply voltage to the engine control unit

Display -V.A.G 1552 less than 12.5 V

Possible cause of fault


AC generator defective, battery heavily

Rectifying fault

Test alternator and battery voltage


Electrical System; Rep. Gr. 27.

discharged
Battery heavily loaded just after start by a

Increase engine speed slightly for a few


minutes and switch off additional consumers.

high charge current or by auxiliary equipment


Transition resistance in the power supply

Check the supply voltage of the engine

or earth connection for engine control unit

control unit Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.

Current consumption with ignition off

Rectify any current drain. Test voltage regulator, replace if necessary Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.

greater than 14.5 V Voltage regulator on generator defective

Overvoltage due to starting aid or quick

Interrogate fault memory Chapter 01-1.

charger

Analysis: Display group 004, display field 3 - coolant temperature

Display -V.A.G 1552 less than 80,0 C

Possible cause of fault


Engine too cold

Rectifying fault

Conduct road test if necessary. Coolant temperature sender or cable con- Test resistances Chapter 24-1.
nection to engine control unit faulty

greater than 115,0 C

Radiator dirty Radiator fan not operational Thermostat for map-controlled engine

Clean radiator. Perform actuator diagnosis Chapter 011.

Test thermostat for map-controlled engine Test resistances Chapter 24-1. Test wiring and plug connections according to current flow diagram.

cooling system faulty


Coolant temperature sender or cable con-

cooling system 1.6l/75 kW Engine, Mechanical Components; Rep. Gr. 19.

nection to engine control unit faulty

constant 30,0 or 49,5 C

Line interruption or short-circuit

Test wiring and plug connections to coolant temperature sender -G62- according to current flow diagram.

Analysis: Display group 004, display field 4 - intake air temperature

Display -V.A.G 1552 constant 9.0 or 30.0 C

Possible cause of fault


Line interruption, short-circuit to positive

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.

Edition 10.04 S00.5135.52.20

Self-diagnosis V

01-5 page 5

01

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Display group 005 Engine operating state


Engine idling Coolant temperature 80 C Text 4 < Display field Operating condition (idling, partial load, enrichment, trailing throttle, full load) Driving speed Engine load Engine speed (idling speed) Specification Idling Analysis --< Readout on display

Reading measured value block 5 xxx rpm 1 xxx.x % 2 xxx km/h 3

0 km/h 15,035,0 % 640900 /rpm

-- 01-5 page 7 01-5 page 2

Display group 006 Basic functions altitude correction factor


Engine idling Coolant temperature 80 C xx.x % 4 < Display field Level correction factor Intake manifold temperature Engine load Engine speed (idling speed) Note on display field 3: The overall temperature range is indicated as nominal value. The display value must be higher than the ambient temperature. Note on display field 4: Altitude NN 1000 m 2000 m Readout +5-10 -5-20 -10-30 Specification -50,010,0 % -38,080,0 C 15,035,0 % 640900 /rpm Analysis -- 01-5 page 5 01-5 page 7 01-5 page 2 < Readout on display

Reading measured value block 6 xxx rpm 1 xxx % 2 xxx.x C 3

01-5 page 6

Self-diagnosis V

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

01

Display group 010 Ignition angle


Engine idling Coolant temperature 80 C xx.x b. TDC 4 < Display field Ignition angle Throttle valve angle (potentiometer 1 -G187-) Engine load Engine speed (idling speed) Note on display field 3: When accelerator fully depressed, the readout must be approx. 100 %. Specification 0,015.0 b. TDC 1,54,0 % 15,035,0 % 640900 /rpm Analysis -- 01-5 page 7 01-5 page 7 01-5 page 2 < Readout on display

Reading measured value block 10 xxx rpm 1 xxx % 2 x.x % 3

Analysis: Display group 010, display field 2 - engine load

Display -V.A.G 1552 less than 15.0 %

Possible cause of fault


lower value can only occur during trailing

Rectifying fault

throttle driving
Unmetered air

Testing intake system for tightness


Chap. 24-2.

greater than 35,0 %

Poor idling (engine not running on all cyl-

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

Test wiring and plug connections to air


mass meter -G70- according to current flow diagram.

Analysis: Display group 010, display field 3 - throttle valve angle

Display -V.A.G 1552 greater than 4.0 %

Possible cause of fault


Engine control unit not adapted to throttle

Rectifying fault

Adapt engine control unit to throttle valve


control unit Chapter 24-6. 24-5.

valve control unit


Throttle valve potentiometer in throttle

Test throttle valve control unit Chapter Remove fault.

valve control unit faulty


Throttle valve jams

Edition 10.04 S00.5135.52.20

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

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Reading measured value block 11 xxx rpm 1 xxx.x C 2 xxx.x C 3

< Readout on display

< Display field Ignition angle

Specification 0,015.0 b. TDC -38,080,0 C 80,0115.0 C 640900 /rpm

Analysis ---- 01-5 page 5 01-5 page 2

Intake manifold temperature Coolant temperature Engine speed (idling speed)

Display group 012 Position of camshaft relative to crankshaft


Engine idling Coolant temperature Reading measured value block 12 xxx rpm 1 xxx.x % 2 xx 3 80 C xx 4 < Display field No. of crankshaft tooth at change of camshaft slope from high - low No. of crankshaft tooth at change of camshaft slope from low - high Engine load Engine speed (idling speed) Specification 8690 Analysis --< Readout on display

2630

---

15,035,0 % 640900 /rpm

01-5 page 7 01-5 page 2

Display group 014 Ignition misfiring recognition


Driving Coolant temperature 80 C Text 4 < Display field Misfiring detection (activated, deactivated) Sum of ignition misfiring Engine load Engine speed (idling speed) Specification activated x 0,0100,0 % 6406500 /rpm Analysis -- 01-5 page 10 ----< Readout on display

Reading measured value block 14 xxxx rpm 1 xxx % 2 xxx 3

01-5 page 8

Self-diagnosis V

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

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.

Display group 015 Ignition misfiring recognition cylinders 1 to 3


Driving Coolant temperature 80 C Text 4 < Display field Misfiring detection (activated, deactivated) Ignition misfiring cyl. 3 Ignition misfiring cyl. 2 Ignition misfiring cyl. 1 Note on display fields 1 to 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. Specification activated x x x Analysis -- 01-5 page 10 01-5 page 10 01-5 page 10 < Readout on display

Reading measured value block 15 xxxx 1 xxx 2 xxx 3

Display group 016 Ignition misfiring recognition cylinder 4


Driving Coolant temperature 80 C Text 4 < Display field Misfiring detection (activated, deactivated) no display no display Ignition misfiring cyl. 4 Note on display field 1: 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. x Specification activated Analysis ------ 01-5 page 10 < Readout on display

Reading measured value block 16 xxxx 1 xxx 2 xxx 3

Edition 10.04 S00.5135.52.20

Self-diagnosis V

01-5 page 9

01

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Analysis: Display group 014, 015 and 016 - ignition misfiring

Display -V.A.G 1552 -

Possible cause of fault

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 spark plugs and spark cables with


spark plug connector Chap. 28-1. Chapter 28-1.

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

Exhaust gas recirculation valve jams

Display group 020 Ignition angle retardation


Driving Coolant temperature 80 C

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 3 through knock control

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.

Analysis 01-5 page 11

0,015.0 b. TDC

0,015.0 b. TDC

01-5 page 11 01-5 page 11 01-5 page 11

0,015.0 b. TDC

0,015.0 b. TDC

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

01

Display group 023 Knock control


Driving Coolant temperature 80 C xx.x BTDC 4 < Display field Ignition angle relief cylinder 4 through knock control Ignition angle relief cylinder 3 through knock control Engine load Engine speed Specification 0,015.0 b. TDC Analysis 01-5 page 11 < Readout on display

Reading measured value block 23 xxxx rpm 1 xxx.x % 2 xx.x BTDC 3

0,015.0 b. TDC 0,0100,0 % 6406500 /rpm

01-5 page 11 -----

Analysis: Display group 020 and 023 - ignition angle retardation

Display -V.A.G 1552 all cylinders great than 15 BTDC

Possible cause of fault


Knock sensor defective Plug connection at knock sensor corrod-

Rectifying fault

Test wiring and plug connections to knock


sensor -G61- according to current flow diagram.

ed
Knock sensor incorrectly tightened Component parts on engine loose poor fuel quality

Slacken knock sensor and tighten again to


20 Nm.

one cylinder clearly deviates from the others

Plug connection at knock sensor -G61-

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

Testing compression pressure 1.6 l/75


kW Engine, Mechanical Components; Rep. Gr. 15

Component parts on engine loose

Tighten loosened attached parts.

Edition 10.04 S00.5135.52.20

Self-diagnosis V

01-5 page 11

01

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Display group 026 Knock sensor voltage signal


Engine idling Coolant temperature 80 C x.xxx V 4 < Display field Knock sensor voltage signal cyl. 4 Knock sensor voltage signal cyl. 3 Knock sensor voltage signal cyl. 2 Knock sensor voltage signal cyl. 1 Specification 0,2002 000 V 0,2002,000 V 0,2002,000 V 0,2002,000 V Analysis --------< Readout on display

Reading measured value block 26 x.xxx V 1 x.xxx V 2 x.xxx V 3

Display group 028 Knock control


Mode basic setting 04 Driving Coolant temperature 80 C Text 4 < Display field Result knock control (Test ON, Test OFF, Syst. O.K., Syst. N.O.K.) Coolant temperature Engine load Engine speed Specification Syst. o.k. Analysis --< Readout on display

Reading measured value block 28 xxx rpm 1 xxx.x % 2 xxx.x C 3

80,0115.0 C 40100 % 6406500 /rpm

01-5 page 5 -----

01-5 page 12

Self-diagnosis V

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

01-6

Self-diagnosis VI

Reading measured value block - display groups 030 to 132


Display group 030 Lambda control
Engine idling Coolant temperature 80 C

Reading measured value block 30 xxx 1 xxx 2 3

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

The third position of the display number changes to 1

under load.

Analysis: Display group 030, display field 1 and 2 - status of lambda control
X 1 1 1 X X Meaning

Lambda probe heater

Lambda probe operational Lambda control active

Edition 10.04 S00.5135.52.20

< Readout on display 4 < Display field no display 110 111


Self-diagnosis VI

01

Specification

Analysis ---- 01-6 page 1 01-6 page 1

01-6 page 1

01

Display group 031, lambda control - lambda values upstream of catalytic converter
Engine idling Coolant temperature 80 C

Reading measured value block 31 x.xxxx 1 x.xxxx 2 3

no display

Lambda nominal value - Bank 1 Lambda actual value - Bank 1

Display group 032, lambda control - lambda learned values


Engine idling Coolant temperature 80 C

Reading measured value block 32 xx.x % 1 xx.x % 2 3

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

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Specification

Analysis ---------

0,99001,0100 0,99001,0100

Specification

Analysis ---- 01-6 page 3 01-6 page 3

-10,010,0 % -14,014,0 %

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

01

Analysis: Display group 032, display field 1 and 2 Lambda learned values

Display -V.A.G 1552 low lambda learned values

Possible cause of fault


Low learned values when idling at normal

Rectifying fault

Disappears after driving on motorway or


changing oil.

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 for lack of leaks and spray pattern of


injectors Chapter 24-2

Test fuel pressure regulator and holding


pressure Chap. 24-2.

Test solenoid valve 1 for activated charcoal filter system with the final control diagnosis Chapter 01-1.

ter constantly open


Air mass meter faulty

Test wiring and plug connections to air


mass meter -G70- according to current flow diagram.

Lambda probe heater faulty or lambda

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

Testing intake system for tightness


Chap. 24-2.

Remove fault.

and throttle valve


Injection valve blocked

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.

Fuel pressure too low Unmetered air at the exhaust manifold

Test fuel pressure regulator and holding


pressure Chap. 24-2.

gasket
Lambda probe heater faulty or lambda

Test lambda probe -G39- and lambda control upstream of catalytic converter Chapter 24-4.

probe dirty

Edition 10.04 S00.5135.52.20

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

Reading measured value block 33 xx.x % 1 x.xx V 2 3

no display

Lambda probe voltage before catalyst Lambda control before catalyst

Note
Re display field 2:

Voltage signal Mixture rich (low level of residual ox-

ygen) is between 0.130...1.500 V.

Voltage signal Mixture rich (high level of residual ox-

ygen) is at approx. 1.500...4.800 V.

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

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Specification

Analysis ---- 01-6 page 4 Chapter 01-5

1,401,60 V

-10,010,0 %

Rectifying fault

Testing lambda probe and lambda control upstream of catalytic con-

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

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)

< Readout on display

Specification B1-S1 O.K.

Analysis ---

--min. 350,0 C 2500...4000 rpm about 1400 rpm1)

-------

for engines with engine code AVU

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

Edition 10.04 S00.5135.52.20

Self-diagnosis VI

01-6 page 5

01

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Voltage of the 4-pin lambda probe in U in mV A: Lambda probe voltage high rich mixture (fuel surplus or air shortage) high CO value B: Lambda probe voltage low 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

Display -V.A.G 1552 constant 1,10 V

Possible cause of fault


Short circuit to positive caused by: Lamb-

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

Short circuit to earth caused by: Lambda

Display group 041 Lambda probe heater


Engine idling Coolant temperature 80 C

Reading measured value block 41 xxxx 1 Text 2 xxxx 3

Text 4

Internal resistance of lambda probe downstream of catalytic converter

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

constant between 0.40 ...0.50 V

Line interruption through: Lambda probe,

Test lambda probe -G130- and lambda


control downstream of catalytic converter Chapter 24-4.

Specification Htg.bC.ON

Analysis ---

-----

Htg.bC.ON

---

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

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)

< Readout on display

Specification B1-S2 O.K.

Analysis ---

0,001,00 V min. 200,0 C 2500...4000 rpm about 1400 rpm1)

-------

for engines with engine code AVU

Display group 046, diagnosis of the catalytic converter efficiency


Mode basic setting 04 BFQ: Brake and accelerator pedal pressed simultaneously, engine running at fast idling AVU: Engine runs in higher speed System in basic setting 46 xxxx rpm 1 xxx.x C 2 x.xx 3 Text 4 < Display field Result of catalytic converter test (Test OFF, Test ON, Cat B1 O.K., Cat B1 N.O.K.) Catalyst efficiency Catalytic converter temperature Engine speed
1)

< Readout on display

Specification Cat B1 O.K.

Analysis ---

0,501,00 min. 400,0 C 2500...4000 rpm 2100 4500 rpm1)

-------

for engines with engine code AVU

Edition 10.04 S00.5135.52.20

Self-diagnosis VI

01-6 page 7

01

Display group 050 Engine speed increase when AC on


Engine idling Coolant temperature 80 C

Reading measured value block 50 xxx rpm 1 xxx rpm 2 Text 3

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)

specified by the engine control unit.


Re display field 4:

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

Reading measured value block 53 xxxx rpm 1 xxxx rpm 2 xx.x V 3

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,

blower, seat heater etc.

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

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Specification

Analysis ------ Chapter 01-5

Compr. ON or compr. OFF ON or OFF

640900 /rpm 640900 /rpm

Specification

Analysis -- Chapter 01-5 -- Chapter 01-5

0,0100,0 % 12,514,5 V

approx. 640...900/ rpm 640900 /rpm

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Display group 054 Engine speed control


Driving Coolant temperature 80 C

Reading measured value block 54 xxx rpm 1 Text 2 xxx.x % 3

xxx.x % 4

Sender 1 for accelerator pedal position Operating condition (idling, partial load, enrichment, trailing throttle, full load) Engine speed

Display group 055 Idling speed stabilisation


Engine idling Coolant temperature 80 C

Reading measured value block 55 xxxx rpm 1 xx % 2 xx.x % 3

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.

Meaning of 5-digit numerical block


X X X X X Meaning 1 x 1 1

PAS pressure switch ON (steering wheel at limit stop) no meaning Gear engaged 1) Air conditioning switched on

1 Air conditioning compressor on


1)

Only on vehicles fitted with automatic gearbox

Edition 10.04 S00.5135.52.20


< 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

Analysis 01-6 page 9 ---- Chapter 01-5

-10,010,0 % -1020 %

640900 /rpm

01-6 page 9

01

Display group 056 Idling speed stabilisation


Engine idling Coolant temperature 80 C

Reading measured value block 56 xxxx rpm 1 xxxx rpm 2 xx % 3

xxxxx 4

Idling regulator Engine speed (actual value)

Engine speed (idling speed - specified value)

Note
Re display field 2:

What is displayed is the specified engine speed (value computed internally in control unit in line with temperature)

specified by the engine control unit.

Display group 060 the EPC system


Mode basic setting 04 Ignition on, engine stopped System in basic setting 60 xx.x % 1 xx.x % 2 x 3

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

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Specification -1020 %

Analysis 01-6 page 9 -------

640900 /rpm 640900 /rpm

Specification

Analysis ---------

100,00,0 % 0,0100,0 %

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Display group 062 Engine speed control EPC system


Ignition on, engine stopped Reading measured value block 62 xx.x % 1 xx.x % 2 xx.x % 3

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.

Display group 063 Kickdown adaptation

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.

The test is finished when ADP O.K. appears in the display.

Edition 10.04 S00.5135.52.20


< 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

Specification 3,048,0 % 6,096,0 % 97,03,0 %

Analysis ---------

3,097,0 %

Specification

Analysis Chapter 24-6

-------

01-6 page 11

01

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Display group 066 cruise control system (only on vehicles with cruise control system)
Engine idling Reading measured value 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

Analysis: Display group 066, display field 4 switch position of CCS


X 1 1 0 0 X X X Meaning Switch -B- to RES Switch -A- pressed (switch -B- to ON) Switch -B- to OFF (not locked or locked) Switch -B- to OFF (only if locked)

01-6 page 12

Self-diagnosis VI

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Display group 070 Diagnosis of activated charcoal filter system (tank vent system)
Mode basic setting 04 Engine idling

Coolant temperature minimum 60 C System in basic setting 70 xxx.x % 1 xx.x % 2 xx.x % 3

Text 4

Idling speed controller variation during TVV diagnosis Lambda controller variation during TVV diagnosis

On/Off ratio of solenoid valve 1 for activated charcoal filter

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.

Display group 074 EGR positioner adaption


Mode basic setting 04 Ignition on, engine stopped System in basic setting 74 x.x V 1 x.x V 2 xxx.x % 3

Text 4

Current poti value Max. stop Zero position

Edition 10.04 S00.5135.52.20


< 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 ---

0,0100,0 % 3,04,8 V 0,31.5 V

-------

01-6 page 13

01
Note

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

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.

Display group 075 - Exhaust gas recirculation


Mode basic setting 04 Engine idling System in basic setting 75 xxxx rpm 1 xxx % 2 xxx.x % 3

Text 4

Valve stroke difference Engine speed (idling speed)

Opening degree potentiometer value

Display group 077 Diagnosis of secondary air injection system


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 77 xxxx rpm 1 2 3 < Readout on display

Text 4

no meaning no meaning Engine speed (idling speed)

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

to display group 074:

Specification

Analysis ---

-10,025,0 % 0,0100,0 %

---- Chapter 01-5

640900 /rpm

Specification

Analysis ---

-------

approx. 1400 rpm

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Display group 095 Single-stage intake manifold changeover


Engine idling Coolant temperature 80 C

Reading measured value block 95 xxxx rpm 1 xx.x % 2 xxx.x C 3

Text 4

Coolant temperature Load Engine speed (idling speed)

Note
Re display field 4:

If the throttle is depressed at approx. 2000 rpm, the status must jump from OFF to ON.

Display group 100 - readiness code


Engine idling Coolant temperature 80 C

Reading measured value block 100 xxxxxxxx 1 xxx.x C 2 xxx s 3

xxxxxxxx 4

Time since engine start Coolant temperature Readiness code

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

Edition 10.04 S00.5135.52.20


< 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

Analysis -- Chapter 01-5 -- Chapter 01-5

80,0115.0 C 640900 /rpm

Analysis ---- Chapter 01-5 01-6 page 15

80,0115.0 C

Air conditioning system (currently no diagnosis/always 0)

Catalytic converter heating (no diagnosis at present/always 0)

01-6 page 15

01

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Display group 120 Traction control system


Driving Reading measured value block 120 xxxx rpm 1 xxx Nm 2 xxx Nm 3 Text 4 < Display field Status Actual engine load Nominal engine load Engine speed Specification TCS active / TCS n. active 0260 Nm 0399 Nm 6406500 /rpm Analysis --------< Readout on display

Display group 122 Gearbox (only automatic gearbox)


Driving Reading measured value block 122 xxxx rpm 1 xxx Nm 2 xxx Nm 3 Text 4 < Display field Status Actual engine load Nominal engine load Engine speed Specification Engine ctl./ no ctl. 0260 Nm 0399 Nm 6406500 /rpm Analysis --------< Readout on display

Display group 125 CAN databus - Messages


For engines with engine code BFQ

Reading measured value block 125 Text 1 Text 2 Text 3

Text 4

< Readout on display

< Display field Status of the air-conditioning system

Specification Clima 1 Combi 1 ABS 1 Gearbox 11)

Analysis -- 01-6 page 17 01-6 page 17 01-6 page 17

Status of the dash panel insert Status ABS Status gearbox


1)

For models with an automatic gearbox

Display group 125 CAN databus - Messages


For engines with engine code AVU

01-6 page 16

Self-diagnosis VI

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Reading measured value block 125 Text 1 Text 2 Text 3

Text 4

Status of the dash panel insert Status gearbox Status ABS


1)

For models with an automatic gearbox

Display group 126 CAN databus - Messages


For engines with engine code BFQ Reading measured value block 126 Text 1 2 3

Status airbag -----

Note

to the display groups 125 and 126:

Specification = 1 means: Connection to the CAN databus cables - control unit.

Specification = 0 means: No connection to the CAN databus cables - control unit.

Analysis: Display groups 125 and 126

Display -V.A.G 1552 if 0 displayed instead of 1

CAN databus connection defective

no CAN databus cables used - control

unit unit

CAN databus cables defective - control

Edition 10.04 S00.5135.52.20


< 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

Analysis -- 01-6 page 17 01-6 page 17 01-6 page 17

Gearbox 11)

Specification

Analysis -- 01-6 page 17 -----

Rectifying fault

Perform the automatic test sequence for


interrogation of all fault memories.

01-6 page 17

01

Display group 130 Diagnosis of mapped cooling


Engine idling AC switched off Reading measured value block 130 xxx.x C 1 xxx.x C 2 xx.x % 3

Text 4

On/off ratio of thermostat Coolant temperature engine outlet

Coolant temperature radiator outlet

Note
to the display fields 1 and 2:

The coolant temperature at engine outlet must always be higher than at radiator outlet.

Display group 131 Diagnosis of mapped cooling


Engine idling AC switched off Reading measured value block 131 xxx.x C 1 xxx.x C 2 xxx.x % 3

xxx.x % 4

Coolant temperature radiator outlet

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

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Specification

Analysis ---

-------

80115 C

Specification

Analysis ---------

0,0100,0 %

0,0100,0 C 0,0115.0 C

80,0115.0 C

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Display group 132 Diagnosis of mapped cooling


Engine idling AC switched off Reading measured value block 132 xxx.x C 1 xxx C 2 xx.x V 3

Text 4

Heating feed potentiometer -G267-

Temperature difference engine and radiator outlet Coolant temperature at radiator outlet (specified temperature)
1)

on vehicles fitted with Climatronic 5.1 V

Status of coolant regulation


X 1 1 x 1 1 1 X X X X X

Checked system

1. Fan level active

2. Fan level active

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.

Edition 10.04 S00.5135.52.20

< Readout on display < Display field Status of coolant regulation xxxxxx 0,24.8 V 0110 C --Self-diagnosis VI

01

Specification
1)

Analysis 01-6 page 19 -------

01-6 page 19

01

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

01-6 page 20

Self-diagnosis VI

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

24

24 Fuel Formation, Injection


24-1 Fuel Injection System

Safety measures
Caution!

The fuel system is under pressure! Place a cloth around the connecting point before releasing hose connections or when opening the system. Then 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

running or at start speed.


Ignition and plug connections must be switched off be-

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-

roundings before releasing.


Place removed parts on a clean surface and cover. Do

not use fuzzy cloths!


Carefully cover or close opened components if the re-

pair is not completed immediately.

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Only install clean parts: Remove spare parts from

their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. in tool boxes etc.).
When the system is open: avoid working with com-

pressed air. Avoid moving the vehicle.


Disconnected plug connections: Protect from dirt and

moisture. Plug together only if dry.

Overview of fitting locations


Note
Components marked with an * are tested by self-diagnosis Chap. 01-1. Components marked with ** are tested by final control diagnosis Chapter 01-1.

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

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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

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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:

Pedal assembly - installed position

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

General notes on the injection system


Repairing the ignition Rep. Gr. 28. The engine control unit is equipped with a self-diagnosis system. Before repairs and also for fault finding, first of all interrogate the fault memory. Also check the vacuum hoses and connections (unmetered air). A minimum voltage of 11.5 V is required for perfect functioning of the electrical components. If after fault finding, repair or inspection of components 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. Certain inspections may cause the control unit to detect and store a fault. It is therefore necessary to interrogate the fault memory after having completed all inspections and repairs, and if necessary erase Chapter 01-1. Safety measures 24-1 page 1. Cleanliless rules 24-1 page 1. Test data, spark plugs Inspection and Maintenance.

1
S24-0459

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Removing and installing parts of the injection system


Note

Components marked with an * are tested by self-diagnosis Chap. 01-1.


1 - Air filter K disassembling and assembling 24-1 page 9 2 - 6 Nm 3 - 10 Nm 4 - 3 Nm 5 - Bottom part of intake manifold 6 - Feed line K white K secured with spring strap clip K from fuel filter 1.6 l/75 Engine, Mechanical Components; Rep. Gr. 20 7 - Return-flow line K blue K secured with spring strap clip K to fuel delivery unit in fuel tank 1.6 l/75 kW Engine, Mechanical Components; Rep. Gr. 20 8 - Fuel rail with injection valves K disassembling and assembling 24-1 page 7 9 - 3-pin plug connection K for engines with engine code AVU K black K for camshaft position sensor -G16310 - 15 Nm 11 - Connector K for coolant temperature sender -G62K 4-pin K black K contacts gold-plated 12 - coolant temperature sender -G62-* K green K with coolant temperature sender -G2K resistances 24-1 page 10 K before removing, reduce pressure in cooling system if necessary 13 - O-ring K replace if damaged 14 - Retaining clip K check tightness 15 - Gasket ring K replace 16 - Connector K black, 2 pin

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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
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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

Disassembling and assembling fuel distributor with injectors


Note

Components marked with an * are tested by self-diagnosis Chap. 01-1.


1 - Retaining clip K check tightness on the injection valve and fuel distributor 2 - Fuel distributor 3 - Injection valves -N30N33 -* K test injected quantity, leak tightness and spray pattern of injectors Chapter 24-2. K resistance: 1217 (at about 20 C) 4 - O-ring K replace K before fitting moisten lightly with clean engine oil 5 - Fuel pressure regulator K inspect Chapter 24-2

S24-0469

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Disassembling and assembling top part of intake manifold


Note
Components marked with an * are tested by self-diagnosis Chap. 01-1. Components marked with ** are tested by final control diagnosis Chapter 01-1.

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

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Disassembling and assembling the air filter


Note

Components marked with an * are tested by self-diagnosis Chap. 01-1.


1 - Air mass meter -G70- with intake air temperature sender -G42- * K resistances for intake air temperature sender -G42 24-1 page 9 2 - Gasket ring 3 - 6 Nm 4 - Air filter top part 5 - Filter insert 6 - 10 Nm 7 - Air filter bottom part 8 - Air deflector 9 - Air intake hose K for secondary air pump 10 - Ventilation hose K for exhaust gas recirculation valve

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 .

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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.

Read out examples:


30 C is within the range -A- and equals a resistance

of 1500...2000 k.
80 C is in range -B- and corresponds to a resistance

of 275...375 .

Test the resistance of the coolant temperature sender


-G62- between contacts C (signal) and D (earth).

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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.

Release the connector catches and unplug the control


unit connectors.

Connect test box -V.A.G 1598/31- to both connectors


of the wiring loom. Earth clip should be connected to the test box and to battery negative. Whether the control unit is additionally connected to the test box or not, is indicated in the particular test procedure.

Perform test as described in the relevant repair sequences. Note

It is therefore necessary to interrogate the fault memory after reconnecting the engine control unit, and if necessary erase Chapter 01-1.

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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

Fuel pump relay o.k., testing Chap. 01-1.


Testing jet formation and tightness

Remove the upper part of the intake manifold


Chapter 24-1.

Remove the fuel rail together with the installed injec-

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.

Unplug the 4-pin connector -1- from the power output


stage -N122- -2-.

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Hold the injectors in the measuring glasses. Operate starter (2nd person required). The injectors
must spray in a pulsing action in line with firing order.

Switch ignition off and inspect injectors for leaks. No


more than 2 drops/min may trickle out. Note
Always fit new seals. If injectors are replaced, erase the learned values and

re-adapt engine control unit Chapter 24-6.

Testing injection rate


Note

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.

Connect terminal to battery positive (+).

Connect battery positive (+) and fuse socket No. 28


with adapter cable and adapter -V.A.G 1348/3-2-. The fuel delivery unit must start running.

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

lightly with clean engine oil.


Insert injectors vertically and into the correct position

in the fuel rail and secure with retaining clips.


Fit fuel distributor with the secured injection valves

onto the cylinder head and and screw up at the same time Chapter 24-1.

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Test fuel pressure regulator and holding pressure


The fuel pressure regulator regulates the fuel pressure in line with the intake manifold pressure. Special tools, test and measuring equipment and auxiliary items required
Pressure gauge appliancee.g. -V.A.G 1318 Adapter -V.A.G 1318/9 Adapter -V.A.G 1318/17-

Test sequence

Remove fuse no. 28 (fuel delivery unit) from the fuse


holder.

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.

Connect up the pressure gauge appliance


-V.A.G 1318- with adapter -V.A.G 1318/9- and -V.A.G 1318/17- to the feed line the hose to the fuel rail.

Open shut-off cock of the pressure measuring device.


Lever points in direction of flow.

Plug fuse no. 28 (fuel delivery unit) into the fuse holder.

Start engine and run in idle. Measure fuel pressure.


Specified value: approx. 0.25 MPa (2.5 bar)

Detach vacuum hose -1- from fuel pressure regulator


-2-. Fuel pressure must rise to approx. 0.3 MPa (3.0 bar). If the specified value is not reached:

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

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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 .

Observe pressure drop at gauge.


If the pressure does not drop:

Test non-return valve of fuel delivery unit 1.6 l/75


kW Engine, Mechanical Components; Rep. Gr. 20 If the pressure again drops:

Inspect pressure measuring device for leaks. Inspect connections, O-rings on the fuel rail and injectors for leaks. If no leaks are found:

Replace the fuel pressure regulator.


Note

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.

Testing the intake system for tightness (unmetered air)


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 Engine leak search spray -G 001 800 A1-

Test condition

Coolant temperature must be at least 80 C.


Test sequence
Note
Because of the vacuum in the intake system the leak

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.

Enter function 08 read measured value block and


select display group 001. Readout on display:
Reading measured value block 700/min 85.0 C 1.5 % 1 -> 10111111

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Observe engine speed in display field 1 and readout


for lambda control upstream of catalytic converter in display field 3.

Systematically spray parts of the intake system with


engine leak search spray. If the engine speed drops or if the displayed lambda control value changes:

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-

Check for proper operation

Initiate final control diagnosis and select vacuum


pump for brakes -V192- Chapter 01-1. If the pump does not run:

Test actuation 24-2 page 6, voltage supply

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:

Proceed with the final control diagnosis up to the end.

24-2 page 6

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24
1 2

Switch off ignition. Check fuse -3- for the vacuum pump.
If fuse is o.k.:

Check voltage supply.


The LED does not flash:

Test wiring.

S24-0465

Check supply voltage

Connect multimeter for voltage measurement (terminal 30) to contacts 1 and 5. Specified value: approx. battery voltage

Connect multimeter for voltage measurement (terminal 15) to contacts 1 and 3.

Switch on ignition.
Specified value: approx. battery voltage If the specified values are reached:

Replace brake vacuum pump -V192- Chassis;


Rep. Gr. 47. If the specified values are not reached:

Test wiring Current Flow Diagrams, Electrical Fault


Finding and Fitting Locations.

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Testing components

Edition 10.04 S00.5135.52.20

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Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

28

28 Ignition System
28-1 Ignition System

General notes on the ignition system


The engine control unit is equipped with a self-diagno-

sis system.
A minimum voltage of 11.5 V is required for perfect

functioning of the electrical components.


Certain inspections may cause the control unit to de-

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

running or at start speed.


Disconnect and connect wires of the injection and pre-

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

the engine starting:

Unplug 4-pin connector -1- from ignition transformer


-2-.

Edition 10.04 S00.5135.52.20

Ignition System

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28

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Removing and installing ignition system


1 - Ignition lead K 48 k K with shielded plug and sparkplug K Use extractor -T10112- to unplug spark plug connector. 2 - Ignition transformer -N, N128K with identification for ignition leads: A = Cylinder 1 B = Cylinder 2 C C = Cylinder 3 D = Cylinder 4 B K with power output stage -N122K resistances 28-1 page 3 3 - 10 Nm 4 - Connector K 4-pin 5 - Knock sensor -G61K contacts of sender and of connector gold-plated 6 - 3-pin plug connection K contacts gold-plated K black 7 - 20 Nm K The tightening torque influences the knock sensor function 8 - Spark plug, 20...30 Nm K type and electrode gap Inspection and Maintenance K use spark plug wrench, (e.g. -3122 B-) for removing and installing 9 - Connector K for engines with engine code AVU K for the camshaft position sensor -G163K contacts of sender and of connector gold-plated K 3-pin 10 - Bracket K for engines with engine code AVU K for camshaft position sensor -G16311 - Camshaft position sensor -G163K for engines with engine code AVU K check 28-1 page 3 12 - Camshaft sprocket K for engines with engine code letters AVU with trim for hall sender K removing and installing 1.6 l/75 kW Engine, Mechanical Components; Rep. Gr. 15 13 - 10 Nm K for engines with engine code AVU 14 - 100 Nm K to release and tighten use counterholder -3415-

A D

28-1 page 2

Ignition System

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

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

Resistances of ignition coils


What is tested is the resistance between contacts 2 + 3 and 1 + 4. Specified value: 4.0...6.0 k (at approx. 20 C)

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

generates an ignition spark per cylinder for each crankshaft rotation.


There is no noticeable effect on the injection if there is

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

the Hall sender -G40-.


The correct setting of the timing can be checked in

measured value block 012 Chapter 01-5.

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-

Edition 10.04 S00.5135.52.20

Ignition System

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28
Test sequence

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

Unplug the plug on the camshaft position sensor


-G163- -arrow-. For engines with engine code BFQ

For engines with engine code AVU Continued for all engines

Switch on ignition. Connect up hand multimeter and measure the voltage


as follows:

For engines with engine code BFQ

28-1 page 4

Ignition System

Edition 10.04 S00.5135.52.20

Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

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

Test wiring Current Flow Diagrams, Electrical Fault


Finding and Fitting Locations

S28-0124

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Ignition System

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Octavia 1997

1.6 l/75 kW Engine, Fuel Injection and Ignition System

28-1 page 6

Ignition System

Edition 10.04 S00.5135.52.20