Skoda OCTAVIA Instruction manual
Service
Workshop Manual
OCTAVIA
Service Department. Technical Information
S00.5109.51.20 Edition 11.98
1.6-ltr./55 kW Engine, 1 AVM
Fuel Injection and Ignition System
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The Service Manual is intended only for use within the Škoda Organisation;
it is not permitted to pass it onto third persons.
© 1998 KODA AUTO a. s.
Printed in CR
ProCarManuals.com
Service
List of Supplements to
OCTAVIA Workshop Manual Edition: 11.98
1.6-ltr./55 kW Engine, 1 AVM Fuel Injection and Ignition System
Replaces List of Supplements - Edition: 08.96
Supple- Edition Subject Article Number
ment
08.96 Basic Edition of Workshop Manual S00.5109.50.20
1 11.98 Supplement to Self-Diagnosis S00.5109.51.20
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Contents ⇒next page.
The Service Manual is intended only for use within the
Škoda Organisation; it is not permitted to pass it onto
third persons.
© 1998 KODA AUTO a. s.
Printed in CR
S00.5109.51.20
ProCarManuals.com
ProCarManuals.com
Edition 11.98
S00.5109.51.20
------------
1 ------------
OCTAVIA Service
Contents
01 Self-diagnosis Page
Self-diagnosis .............................................................................................................................. 01-1
- Features of self-diagnosis ........................................................................................................ 01-1
- Technical data of self-diagnosis ............................................................................................... 01-1
- Connecting vehicle system tester V.A.G 1552 and selecting engine electronics control unit .. 01-2
- Interrogating and erasing fault memory.................................................................................... 01-4
- Fault table ................................................................................................................................. 01-6
- Final control diagnosis .............................................................................................................. 01-12
- Reading measured value block and basic setting .................................................................... 01-16
- Lists of display groups .............................................................................................................. 01-16
24 Fuel Preparation/Fuel Injection Page
Servicing fuel injection system .................................................................................................. 24-1
- List of fitting locations ............................................................................................................... 24-1
- Servicing fuel injection part ...................................................................................................... 24-3
- Disassembling and assembling fuel rail and injectors ............................................................. 24-6
- Disassembling and assembling intake manifold ...................................................................... 24-6
- Disassembling and assembling air filter ................................................................................... 24-7
- Safety precautions .................................................................................................................... 24-9
- Rules for cleanliness ................................................................................................................ 24-9
- Technical data .......................................................................................................................... 24-10
- Performing basic setting ........................................................................................................... 24-10
- Testing lambda probe and lambda control ............................................................................... 24-12
- Testing lambda probe heater .................................................................................................... 24-13
- Testing lambda probe signal wire and actuation ...................................................................... 24-14
- Testing operating states of engine............................................................................................ 24-16
- Testing throttle valve control unit .............................................................................................. 24-18
- Testing intake manifold pressure sender ................................................................................. 24-26
- Testing vehicle speed signal ..................................................................................................... 24-29
- Testing altitude sender ............................................................................................................. 24-31
- Testing intake air temperature sender ...................................................................................... 24-34
- Testing voltage supply for control unit ...................................................................................... 24-38
- Adapting engine electronics control unit to electronic immobiliser ........................................... 24-40
- Testing injectors........................................................................................................................ 24-41
- Testing fuel pressure regulator and holding pressure .............................................................. 24-44
- Testing intake system for leaks (unmetered air) ...................................................................... 24-46
- Testing intake air preheater ...................................................................................................... 24-48
- Testing activated charcoal filter solenoid valve (N80) .............................................................. 24-49
- Testing fuel pump relay and actuation ...................................................................................... 24-52
- Replacing engine control unit ................................................................................................... 24-55
28 Ignition System Page
Servicing ignition system ........................................................................................................... 28-1
- Summary of components of ignition part .................................................................................. 28-1
- Disassembling and assembling distributor ............................................................................... 28-2
- Safety precautions .................................................................................................................... 28-3
- Setting data, spark plugs .......................................................................................................... 28-3
- Testing and setting ignition timing ............................................................................................ 28-4
- Testing Hall sender ................................................................................................................... 28-5
- Testing ignition transformer ...................................................................................................... 28-7
- Testing output stage for ignition transformer ............................................................................ 28-7
- Testing knock sensor................................................................................................................ 28-9
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OCTAVIA Self-Diagnosis 01
Edition 11.98
S00.5109.51.20
------------
01-1 ------------
Self-diagnosis
Note:
The self-diagnosis monitors only a part of the
fuel injection and ignition system. Always use
Binder 2 for fault finding.
Features of self-diagnosis
The engine control unit -J382- is equipped with
a fault memory. The fault memory is designed
as a permanent memory.
If faults occur in the monitored sensors or
components, these are stored in the fault
memory with an indication of the type of fault.
Faults which occur only temporarily (spora-
dically), are also printed out with the addition
„sporadically occurring fault“. Such faults are
identified in the display by the addition „/SP“.
The cause of a sporadic fault may be, for
example, a loose contact or a short-time open
circuit in the wiring. If a sporadic fault no longer
occurs within 40 engine starts, it is erased from
the fault memory.
The faults stored can be read with the vehicle
system tester V.A.G 1552 or with the fault reader
V.A.G 1551 ⇒page 01-4.
After rectifying the fault or faults, it is necessary
to erase the fault memory ⇒page 01-4.
Notes:
♦
The description which follows relates only to
vehicle system tester V.A.G 1552 using
programme card version 3.0 or higher.
♦
The procedure for using the fault reader
V.A.G 1551 with integrated printer is similar
although slight differences in the readouts in
the display are possible.
Technical data of self-diagnosis
Interrogating control unit version
The control unit version is displayed when you
connect the vehicle system tester V.A.G 1552
and select the engine electronics control unit
⇒page 01-2.
Functions available when using vehicle
system tester V.A.G 1552
Please refer to the table which follows for the
requirements which have to exist if you wish to
select the desired functions.
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OCTAVIA
01 Self-Diagnosis
Edition 11.98
S00.5109.51.20
------------
01-2 ------------
Function Requirement
Engine Engine
not idling
running,
ignition on
02 Interrogate fault memory1) yes1) yes
03 Final control diagnosis yes no
04 Basic setting yes2) yes3)4)
05 Erase fault memory yes yes
06 End output yes yes
08 Read measured value yes yes
block
1) Only if engine does not start (starter must
operate for at least 6 seconds).
2) Must be performed after completing the
following work:
Replacing engine control unit, throttle valve
control unit or engine, or disconnecting
battery.
3) Only possible once coolant temperature is
higher than 80 °C. This function is inhibited
up until this moment.
4) Must be performed for testing and setting
ignition timing.
Connecting vehicle system tester
V.A.G 1552 and selecting engine
electronics control unit
Special tools, testers and aids required
♦Vehicle system tester V.A.G 1552 with cable
V.A.G 1551/3
Test conditions
lBattery voltage at least 11 V
lFuse 12 o.k.
lEarth connections at front of connector
housing and in cylinder head o.k.
Procedure
K- Connect vehicle system tester V.A.G 1552
with cable V.A.G 1551/3.
ProCarManuals.com
OCTAVIA Self-Diagnosis 01
Edition 11.98
S00.5109.51.20
------------
01-3 ------------
After the vehicle system tester has been
connected:
- Depending on the desired function, you must:
switch on ignition or
start the engine ⇒page 01-1, table of
„Available Functions“.
Notes:
♦
If the readouts which appear in the display
are not the same as shown in the procedure:
⇒Operating Instructions of vehicle system
tester
♦
If ”Fault in data transfer!” is displayed
because of an incorrect entry, disconnect
cable at fault reader, plug in again and repeat
the steps.
KReadout in display:
Note:
Operate the vehicle system tester by referring
to the readouts which appear in the display.
- Press the keys 0 and 1 for the address word
„Engine electronics“ and confirm the entry
with the key Q.
KThe control unit identification appears in the
display, e.g.:
♦032 906 014A = Part No. of control unit
♦Marelli 1AVM = System designation and
version
♦2162 = Programme status number
- Press the →key.
KReadout in display:
- Refer to repair operations for further proce-
dure.
List of engine control units
Production Control unit Programme No.
designation
08.96 ä03.97 032906014 A 2162
04.97 ä01.98 032906014 E 2170
02.98 032906014 E 2177
03.98 ä032906014 F 2231
The old type of control units can be replaced by
control units with the designation 032906014 F
when they are replaced.
Test of vehicle systems HELP
Enter address word XX
032906014A Marelli 1AVM 2162 →
Test of vehicle systems HELP
Select function XX
ProCarManuals.com
OCTAVIA
01 Self-Diagnosis
------------
01-4 ------------ Edition 08.96
S00.5109.50.20
Interrogating and erasing fault
memory
Special tools, testers and aids re uired
♦Vehicle system tester V.A.G 1552 with cable
V.A.G 1551/3
Procedure
- Connect the vehicle system tester V.A.G
1552 an select the engine electronics cont-
rol unit with the a ress wor 01. The
engine shoul be i ling when carrying out
this step.
(Connecting vehicle system tester an se-
lecting control unit for engine electronics
⇒page 01-2).
Only if engine does not start:
-Switch the ignition on.
KRea out on isplay:
- Press the keys 0 an 2 for the function
interrogate fault memory an confirm the
entry with the key Q.
KThe number of store faults or no fault recognis-
e ! appears in the isplay.
If one or several faults are stored:
The store faults are isplaye one after the
other.
KRea out on isplay:
- Press the keys 0 an 5 for the function erase
fault memory an confirm entry with the key
Q.
Note:
If you switched off the ignition between interro-
gating fault memory and erasing fault memory,
the fault memory is then not erased.
Test of vehicle systems HELP
Select function XX
X faults recognise !
Test of vehicle systems HELP
Select function XX
ProCarManuals.com
OCTAVIA
S00.5109.50.20
------------
------------
KReadout on display:
- Press the → key.
- Press the keys 0 and 6 for the function end
data transfer and confirm the entry with the
key Q.
- Rectify the faults displayed by referring to the
fault table ⇒ page 01-6.
- After you have rectified the faults, you then
have to carry out a road test.
During this road test, the following operating
conditions should be met:
♦The coolant temperature should rise to
more than 80 °C.
♦Once this temperature is reached, the
operating states of
idling
part throttle
full throttle
overrun
have to be achieved several times.
♦Engine speed should be increased to
more than 3500 rpm at full throttle.
- Once again interrogate fault memory of the
control unit.
- Press the → key.
KReadout on display:
- Press the keys 0 and 6 for the function end
data transfer and confirm the entry with the
key Q.
Note:
If not fault has been recognised by the self-
diagnosis, use the relevant fault table in binder
2 Fault Finding Engine - Mechanical Compo-
nents for continuing fault finding
Test of vehicle systems →
Fault memory is erased!
Test of vehicle systems HELP
Select function XX
ProCarManuals.com
OCTAVIA
01 Self-Diagnosis
------------
------------ Edition
S00.5109.50.20
Notes:
♦The fault table is arranged in accordance with the 5-digit
fault code indicated on the left.
♦Explanations regarding the types of faults (e.g. open
circuit/short circuit to earth)
⇒
♦If components are displayed as faulty
First of all test the wiring and plug connections to these
components and also the earth cables of the system
on the basis of the current flow diagram. Only replace
component if no fault is found here. This applies
particularly if faults are indicated as sporadic faults
(SP).
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OCTAVIA
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ProCarManuals.com
OCTAVIA
01 Self-Diagnosis
------------
------------ Edition
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ProCarManuals.com
OCTAVIA Self-Diagnosis 01
Edition 11.98
S00.5109.51.20
------------
------------
Readout on V.A.G 1552
00530
Throttle valve positioner/
potentiometer -G881)
Open/short circuit to
positive
Short circuit to earth
00532
Supply voltage
Signal too large
00537
Lambda control
Control limit exceeded
Possible cause of fault
♦Open circuit in wiring or
short circuit to positive
♦G88 faulty
♦Cable has short circuit to
earth
♦G88 faulty
♦Battery voltage greater
than 16.3 V
♦Lambda probe heater
faulty
♦Leak in exhaust system
between cylinder head and
catalytic converter
♦Ignition misfiring
Possible effects
♦Cold start problems
♦Idling speed not within
tolerance
♦Cold idling problems
♦Irregular idling
♦No idling speed adaptation
♦No lambda control
♦Poor drivability
♦Poor idling
♦Emission levels not o.k.
Rectifying faults
- Test G88
⇒page 24-17, Testing
throttle valve control unit
- Test generator
⇒Current Flow Diagrams,
Fault Finding Programmes
and Fitting Locations
- Test lambda probe heater
for open circuit in wiring
⇒page 24-13
- Inspect exhaust system for
leaks
- Testing ignition system
⇒page 28-1
1) The throttle valve positioner/potentiometer (G88) is part of the throttle valve control unit (J338).
ProCarManuals.com
OCTAVIA
01 Self-Diagnosis
Edition 11.98
S00.5109.51.20
------------
------------
Readout on V.A.G 1552
00537
Lambda control
Control limit exceeded
Control limit not reached
Possible cause of fault
♦Fuel pump faulty
♦Fuel pressure regulator
faulty
♦Lambda probe faulty -
change in characteristic as
a result of effect of chemi-
cals
♦Fuel tank empty
♦Injector(s) faulty (blocked)
♦Short circuit to earth or
positive, or open circuit in
wiring between lambda
probe and engine control
unit
♦Short circuit to earth or
positive, or open circuit in
wiring between lambda
probe and engine control
unit
♦Fuel pressure too high
♦Activated charcoal filter
solenoid valve N80 leaking
or jamming
♦Lambda probe faulty
- change in characteristic
as a result of effect of
chemicals
♦Injector(s) faulty (always
open)
Possible effects
♦No lambda control
♦Poor drivability
♦Poor idling
♦Emission levels not o.k.
♦No lambda control
♦Poor drivability
♦Poor idling
♦Emission levels not o.k.
♦Increased fuel
consumption
Rectifying faults
- Test fuel pump
⇒Engine, Mechanical
Components; Repair
Group 20
- Test fuel pressure regulator
⇒page 24-44
- Replace lambda probe
- Refuel vehicle
- Test injectors ⇒page 24-41
- Test lambda control
⇒page 24-12
- Test lambda control
⇒page 24-12
- Test fuel pressure regulator
⇒page 24-44
- Test N80 ⇒page 01-12,
Final control diagnosis
- Replace lambda control
- Test injectors ⇒page 24-41
ProCarManuals.com
OCTAVIA Self-Diagnosis 01
Edition 11.98
S00.5109.51.20
------------
------------
Readout on V.A.G 1552
00609
Ignition output 1
Short circuit to positive
Open/short circuit to
earth
01087
Basic setting not
performed
01126
Engine speed signal
Short circuit to positive
Short circuit to earth
01247
Solenoid valve 1 for acti-
vated charcoal filter -N80
Open/short circuit to
earth
Short circuit to positive
Possible cause of fault
♦Cable to ignition trans-
former has short circuit to
positive
♦Open circuit in earth cable
♦Cable has short circuit to
earth
♦Engine control unit not
matched to engine
♦Open circuit in wiring or
short circuit to positive
♦Cable has short circuit to
earth
♦Open circuit in wiring or
short circuit to earth
♦N80 faulty
♦Cable has short circuit to
positive
♦N80 faulty
Possible effects
♦Engine does not start
♦Rev counter does not
operate
♦Irregular idling
♦Smell of fuel
Rectifying faults
- Test output stage of ignition
transformer ⇒page 28-7
- Perform basic setting
⇒page 24-10
- Test engine speed signal
⇒page 01-12, Final
control diagnosis
- Test N80
⇒page 01-12, Final
control diagnosis
ProCarManuals.com
OCTAVIA
01 Self-Diagnosis
Edition 11.98
S00.5109.51.20
------------
01-10 ------------
Readout on V.A.G 1552
01249
Injector cylinder 1 -N30
Short circuit to positive
Open/short circuit to
earth
01250
Injector cylinder 2 -N31
Short circuit to positive
Open/short circuit to
earth
01251
Injector cylinder 3 -N32
Short circuit to positive
Open/short circuit to
earth
Possible cause of fault
♦N30 faulty
♦Cable has short circuit to
positive
♦N30 faulty
♦Open circuit in earth
♦Cable short circuit to earth
Possible effects
♦Increased emission levels
♦Poor starting characteristics
♦Drivability problems
♦Poor throttle response
♦Irregular idling
Rectifying faults
- Test N30...N33
⇒page 24-41, Testing
injectors
Fault code 01249, cyl. 1
Fault code 01249, cyl. 1
ProCarManuals.com
OCTAVIA
S00.5109.50.20
------------
------------
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ProCarManuals.com
OCTAVIA
01 Self-Diagnosis
------------
------------ Edition 08.96
S00.5109.50.20
diagnosis
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Notes:
To repeat final control diagnosis without starting
the engine in between, switch off ignition for
about 20 seconds.
ProCarManuals.com
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