Skoda OCTAVIA Instruction manual
Service
List of Supplements to
OCTAVIA Workshop Manual dition: 01.04
1.9l/81 kW (TDI) ngine, Fuel Injection and Glow Plug System
Replaces List of Supplements - dition: 10.03
Supple- dition Subject Article Number
ment
03.98 Basic dition S00.5122.50.20
1 02.99 Modifications to Fault Codes S00.5122.51.20
2 02.01 Modifications to Vehicles 08.00 äS00.5122.52.20
3 01.02 Supplement to fault code S00.5122.53.20
4 10.03 Readiness code, Supplement to Repair Group 01 S00.5122.54.20
5 01.04 Supplement to Repair Group 01 S00.5122.55.20
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
koda Organisation; it is not permitted to pass it on to
third persons.
© 2004 KODA AUTO a. s.
Printed in Czech Republic
S00.5122.55.20
ProCarManuals.com
dition 01.04
S00.5122.55.20
------------
I ------------
OCTAVIA Service
Contents
01 Self-Diagnosis Page
Self-Diagnosis.............................................................................................................................. 01-1
- Properties of the self-diagnosis ................................................................................................ 01-1
- echnical data of self-diagnosis ............................................................................................... 01-1
- Connecting tester V.A.G 1552 and select engine electronics control unit ................................ 01-2
- Interrogating and erasing fault memory .................................................................................... 01-5
- Fault table ................................................................................................................................. 01-8
Actuator diagnosis ...................................................................................................................... 01-20
- Performing actuator diagnosis ................................................................................................. 01-20
- Basic setting ............................................................................................................................. 01-24
- Coding control unit ................................................................................................................... 01-26
Readiness code ........................................................................................................................... 01-27
- Reading readiness code ........................................................................................................... 01-27
- Generate readiness code ......................................................................................................... 01-29
Measured value blocks ............................................................................................................... 01-31
- Reading measured value block ................................................................................................ 01-31
- Display nominal values for general vehicle inspection ............................................................. 01-32
- Display nominal values for injection pump ............................................................................... 01-36
- Display nominal values for engine idling .................................................................................. 01-42
- Display nominal values for exhaust gas recirculation .............................................................. 01-47
- Display nominal values for temperature sensor ....................................................................... 01-48
- Display nominal values for automotive power .......................................................................... 01-49
- Display nominal values for charge pressure control ................................................................ 01-54
23 Fuel Formation/Injection Page
Servicing a diesel direct fuel injection system......................................................................... 23-1
- Safety measures ...................................................................................................................... 23-1
- Rules for cleanliness ................................................................................................................ 23-1
- Overview of fitting locations ...................................................................................................... 23-2
- Servicing injection pump .......................................................................................................... S
- Servicing fuel filter .................................................................................................................... S
- Servicing throttle mechanism ...................................................................................................S
- Adjusting sender for accelerator pedal position ....................................................................... S
- Disassembling and assembling air filter ................................................................................... S
- Removing and installing injection pump ................................................................................... S
- Dynamically testing and setting commencement of injection ................................................... S
- Removing and installing and testing injection nozzles ............................................................. S
- Replacing O-ring at cover for injection timing device ............................................................... S
- Wiring and Component est with est Box V.A.G 1598/22 ...................................................... S
- Replacing engine electronics control unit ................................................................................. S
Inspecting the charge air pressure system .............................................................................. 23-4
- Inspecting charge air pressure ................................................................................................. 23-4
- Inspecting charge pressure control solenoid valve (N75) ........................................................ 23-6
- Inspecting intake manifold temperature sender (G72) ............................................................. S
- Inspecting intake manifold pressure sender (G71) and altitude sender ................................... S
S Repair operations ⇒ 1.9l/66 kW ( DI) Engine, Fuel Injection and Glow Plug System; Vehicles for
Model Year 98 (08.97 ä)
ProCarManuals.com
Service OCTAVIA
dition 01.04
S00.5122.55.20
------------
II ------------
Testing injection control ............................................................................................................. S
- esting injection timing device control range ............................................................................ S
- esting the commencement of injection valve (N108) ............................................................. S
- Inspecting fuel temperature sender .......................................................................................... S
Inspecting exhaust gas recirculation system ........................................................................... S
- Hose layout plan for the charge pressure regulation, the exhaust gas recirculation and
intake manifold flap .................................................................................................................. 23-9
- Inspecting exhaust gas recirculation ........................................................................................ 6
- Inspecting electromagnetic exhaust gas recirculation valve .................................................... S
- Inspecting air mass meter (G70) .............................................................................................. 23-10
Inspecting control units input quantities .................................................................................. S
- esting voltage supply for diesel direct injection system .......................................................... S
- esting engine speed sender (G28) ......................................................................................... S
- esting needle lift sender (G80) ...............................................................................................S
- esting coolant temperature sender (G62) ............................................................................... S
- esting brake light switch (G149) and brake pedal switch (N146) ........................................... S
- esting modulating piston movement sender and metering adjuster ....................................... 23-13
- esting accelerator pedal position sender (G79) ...................................................................... S
Testing auxiliary signals ............................................................................................................. S
- esting signals from/to the air conditioning system .................................................................. S
- esting clutch pedal switch (F36) ............................................................................................. S
- esting speed signal ................................................................................................................. S
- esting engine speed signal ..................................................................................................... S
- Activating or deactivating cruise control system ....................................................................... S
- esting cruise control system ................................................................................................... S
- esting databus ........................................................................................................................ S
Servicing intake manifold ........................................................................................................... S
- Inspecting the change-over of the intake manifold flap ............................................................ 6
28 Glow plug system Page
Inspecting glow plug system .....................................................................................................S
- Inspecting proper operation ...................................................................................................... S
- Inspecting glow plugs ............................................................................................................... S
- Inspecting glow period warning lamp ....................................................................................... S
S Repair operations ⇒ 1.9l/66 kW ( DI) Engine, Fuel Injection and Glow Plug System, Vehicles for
Model Year 98 (08.97 ä)
6 Repair operations ⇒ 1.9l/66 kW ( DI) Engine, Fuel Injection and Glow Plug System, Vehicles for
Model Year 98 (08.97 ä), Hose layout plan ⇒ 1.9l/81 kW ( DI) Engine, Fuel Injection and Glow Plug Sys-
tem; Page 23-8
ProCarManuals.com
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Notes:
♦The following description only relates to the
vehicle system tester V.A.G 1552 using the
current program card.
♦If the display of the vehicle system tester
reads Information in the literature the re-
quired text is to be found in the fault table
according to the fault code.
♦The use of fault read-out scan tool V.A.G 1551
(using current program card) with integrated
printer or VAS 5051 is similar. A minor devia-
tion on the display read-out is possible.
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⇒"
------------
-------------
ProCarManuals.com
OCTAVIA
01 Self-Diagnosis
Edition 02.01
S00.5122.52.20
------------
01-2 ------------
Available functions when using vehicle sys-
tem tester V.A. 1552
Please refer to the table below for the require-
ments when you wish to select the desired func-
tions.
Function Requirement
Engine off, Engine
ignition idling
switched on
01 Interrogate control unit yes yes
version
02 Interrogate fault memory yes1 yes
03 Final control diagnosis yes yes
04 Basic setting no yes
05 Erase fault memory yes yes
06 End output yes yes
07 Code control unit yes no
08 Read measured value yes yes
block
1 Only if engine does not start (starter must
be operated for at least 6 s .
Connecting vehicle system tester
V.A. 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, 3A, 3B or 3C
Test conditions
lBattery voltage at least 11.5 V
lFuse 12 o.k.
lEarth connections at gearbox and on left
below battery o.k.
ProCarManuals.com
OCTAVIA Self-Diagnosis 01
Edition 03.98
S00.5122.50.20
------------
01-3 ------------
Procedure
K- Connect the vehicle system tester V.A.G
1552 with the cable V.A.G 1551/3.
After the vehicle system tester has been con-
nected:
- epending on the function you desire, you
have to:
Switch on the ignition or start the engine
⇒ page 01-2, table of Functions available.
If the readouts which appear in the display are
not those shown in the procedure, please refer
to the following notes:
Notes:
♦If Fault in data transfer! appears because
of an input error, unplug cable at the fault
reader, plug in again and once again carry
out the steps.
K♦If one of the following messages appears in
the display, carry out fault finding according
to the Fault Finding Programme Diagnosis
Cable
⇒Current Flow iagrams, Electrical Fault
Finding and Fitting Locations binder, or
⇒Operating Instructions of Vehicle System
Tester
Note:
Operate the vehicle system tester according to
the readout which appears in the display.
KReadout in display:
- Press the keys 0 and 1 for the address word
Engine electronics and confirm the entry
with the key Q.
Test of vehicle systems HELP
Fault in communication build-up
Test of vehicle systems HELP
K wire not switching to earth
Test of vehicle systems HELP
K wire not switching to positive
Test of vehicle systems HELP
Enter address word XX
Test of vehicle systems HELP
Control unit does not answer!
ProCarManuals.com
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Notes:
If the control unit version displayed does not cor-
respond to the vehicle, replace the control unit
⇒
3811%#9!)-(;<.-5
,
Incorrect coding of the engine control unit re-
sults in:
♦poor driveability (jerking when changing
gears, load alteration shock etc.)
♦Increase in fuel consumption
♦Increase in pollution
♦Storage of non-existent faults in fault memory
------------
-------------
ProCarManuals.com
OCTAVIA
S00.5122.52.20
------------
01-5 ------------
♦Functions not being performed
♦Reduction in gearbox life
If the coding does not match the corresponding
version in the vehicle:
- Check coding of engine control unit
⇒
page
01-26, Coding engine control unit.
- Press → ke .
KReadout in displa :
- For the remaining procedure
⇒
Repair in-
structions.
♦Vehicle s stem tester V.A.G 1552 with cable
V.A.G 1551/3, 3A, 3B or 3C
- Connect vehicle s stem tester V.A.G 1552
and select engine electronics control unit (ad-
dress word 01). The engine should be idling
for this step.
(Connecting vehicle s stem tester and se-
lecting engine electronics control unit
⇒
page
01-2).
Onl if the engine does not start:
- Switch the ignition on.
KReadout in displa :
- Enter 02 for the function Interrogate fault
memor and confirm the entr with the ke
Q.
KThe number of stored faults or No fault recog-
nized! appears in the displa .
- Press → ke .
KReadout in displa :
- End output (function 06).
Test of vehicle s stems HELP
Select function XX
Test of vehicle s stems HELP
Select function XX
X faults recognized!
Test of vehicle s stems HELP
Select function XX
ProCarManuals.com
OCTAV1A
01 Self-Diagnosis
dition 01.04
S00.5122.55.20
If one or several faults are stored:
-→ Press key.
KRead-out of fault number on display, e.g.:
-→ Press key.
KFault source and fault type appear in the dis-
play, e.g.:
-→ Press key.
he stored faults are displayed in sequence.
-→ Press key.
KRead-out on display:
- End output (function 06).
- Rectify fault by referring to the fault table
⇒ page 01-8.
Note:
When carrying out test and removal and instal-
lation operations, faults, such as connectors
unplugged, may also be detected by other con-
trol units. This is why, when the work is con-
cluded, that it is necessary to interrogate and
erase the fault memory on all control units. For
this you must proceed as follows:
- Enter 00 for the address word Automatic
check sequence and confirm entry with Q
key. he -V.A.G 1552- sends all known ad-
dress words in sequence.
rasing fault memory
Test condition
lRectifying fault
Note:
After fault elimination the fault memory must
again as described be interrogated and subse-
uently erased.
For vehicles 08.03 ä
Whenever the fault memory is erased, it is nec-
essary to generate a readiness code ⇒ page
01-29.
- Connect vehicle system tester -V.A.G 1552-
and select the engine electronics control unit
(address word 01). he engine must be run-
ning in idle.
(Connect vehicle system and select engine
electronics control unit ⇒ page 01-2).
------------
01-6 -------------
→
Fault number: 00542
Needle lift sender -G80 →
Short-circuit to earth
Vehicle system test HELP
Select function XX
ProCarManuals.com
OCTAVIA
S00.5122.52.20
------------
------------
Test of vehicle systems HELP
Select function XX
X faults recognized!
Test of vehicle systems HELP
Select function XX
Test of vehicle systems →
Fault memory is erased!
KReadout in display
- Enter 02 for the function Interrogate fault
memory and confirm the entry with the key
Q.
KThe number of stored faults appears in the dis-
play.
The stored faults are displayed one after the
other.
KAfter the stored faults have been displayed, the
following readout appears
- Enter 05 for the function Erase fault me-
mory and confirm the entry with the key Q.
KReadout in display
Note:
If the ignition is switched off between Interro-
gating fault memory and Erasing fault
memory, the fault memory is not erased.
- Press → key.
- Enter 06 for the function End output and
confirm the entry with the key Q.
- Conduct a road test. After this, once again
interrogate the fault memory. There must not
be any further faults displayed.
ProCarManuals.com
, 1!
%,,-
S00.5122.54.20
#2
Notes:
♦For vehicles 08.98 ä, different fault codes
with the same or similar texts are displayed.
The required text is to be selected in the fault
table according to the fault code.
♦If the display of the vehicle system tester
reads Information in the literature the re-
quired text is to be found in the fault table
according to the fault code.
♦The fault table is ordered according to the
fault code on the left.
♦Explanations concerning the types of faults
(e.g. Interruption or short-circuit to earth):
⇒
7 $
♦If components are output as faulty:
First check all cables and connectors to these
components as well as the earth connections
according to the Current Flow Diagram. Re-
place the component only if this test does
not reveal any fault. This applies in particu-
lar for faults that are output as sporadically
occurred (SP) faults.
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------------
-------------
ProCarManuals.com
OCTAVIA Self-Diagnosis 01
Edition 02.99
S00.5122.51.20
Readout on V.A.G 1552
Fault number Possible cause of fault Possible effects Rectifying fault
old
00522
Coolant temperature
sender -G62
Short circuit to
earth
Open/short circuit
to positive
00527
Intake manifold tem-
perature sender -G72
Short circuit to
earth
Open/short circuit
to positive
new
17663
17664
17568
17569
♦-G62 faulty
♦Cable has short circuit to
earth
♦-G62 faulty
♦Open circuit in wiring or
cable has short circuit to
positive
♦-G72 faulty
♦Cable has short circuit to
earth
♦-G72 faulty
♦Open circuit in wiring or
short circuit to positive
♦Black exhaust when start-
ing
♦Engine preheater does not
operate
♦Preglowing always oper-
ates for about 20 seconds
♦Engine preheater does not
operate
- Test coolant temperature
sender
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Test intake manifold tem-
perature sender
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
------------
01-9 ------------
ProCarManuals.com
OCTAVIA
01 Self-Diagnosis
Edition 02.99
S00.5122.51.20
Readout on V.A.G 1552
Fault number Possible cause of fault Possible effects Rectifying fault
------------
01-10 ------------
old
00532
Supply voltage
Implausible signal
as appropriate
Voltage supply tml.
15
Voltage too low
00539
Fuel temperature
sender -G81
Short circuit to
earth
Open/short circuit
to positive
♦Control unit was con-
nected when ignition on
♦Open circuit in wiring or
short circuit
♦Voltage not present when
ignition on (terminal 15)
♦Diesel direct injection sys-
tem control unit -J248
faulty
♦Voltage supply relay termi-
nal 30 (J322) faulty
♦-G81 faulty
♦Cable has short circuit to
earth
♦-G81 faulty
♦Open circuit in wiring or
short circuit to positive
♦Connector for injection
pump separated
new
18008
17570
17571
♦Engine does not start
♦Engine stops
♦Reduced output
♦Increased emission levels
♦Several faults stored
♦Engine stops
- Erase fault memory and
continue checking vehicle
- Test voltage supply of die-
sel direct injection system
control unit
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Test voltage supply of ter-
minal 15
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Replace control unit
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Test voltage supply of die-
sel direct injection system
control unit
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Test fuel temperature
sender
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Check plug connection for
injection pump
ProCarManuals.com
OCTAVIA Self-Diagnosis 01
Edition 02.99
S00.5122.51.20
Readout on V.A.G 1552
Fault number Possible cause of fault Possible effects Rectifying fault
old
00542
Needle lift sender
-G80
Short circuit to
earth
Implausible signal
Open/short circuit
to positive
new
17653
17654
17655
♦-G80 faulty
♦Open circuit in wiring or
short circuit
♦Fuel supply (was) inter-
rupted: tank has run
empty, feed line or filter
blocked, system drawing
in air
♦(Sporadic) open circuit in
wiring to fuel cut-off valve
♦Sender plate of engine
speed sender bent or
loose
♦-G80 faulty
♦Injection pump faulty
♦-G80 faulty
♦Sporadic open circuit in
wiring (cable break)
♦Glow indicator lamp
flashes
♦Rough engine running
♦Reduced output
♦Increased emission levels
♦Fault 00550 Commence-
ment of injection control
control difference may be
stored
♦Misfiring, jerking
♦Engine stops
♦Misfiring
♦Misfiring at exactly
3000 rpm
♦Misfiring, jerking (particu-
larly at high revs)
♦Fault 01268 quantity ad-
juster control difference
stored
♦Irregular engine running,
misfiring
♦No throttle response after
overrun
♦Glow indicator lamp
flashes
♦Misfiring, jerking
♦Reduced output
- Test needle lift sender
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Check fuel system
- Check cable connection
and plug connection at in-
jection pump
- Take off oil pan and in-
spect sender plate
- Replace needle lift sender
- Replace injection pump
- Test needle lift sender
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
------------
01-11 ------------
ProCarManuals.com
OCTAVIA
01 Self-Diagnosis
Edition 02.99
S00.5122.51.20
Readout on V.A.G 1552
Fault number Possible cause of fault Possible effects Rectifying fault
old
00550
Commencement of
injection control
Control difference
new
17656
♦Commencement of deliv-
ery not o.k.
♦Adjustment travel of injec-
tion pump blocked (dirt,
swarf)
♦Engine was stalled (within
the last 50 starts)
♦Fuel feed (was) interrupted:
tank has run empty, feed
line or filter blocked, system
drawing in air
♦Open circuit in wiring to
commencement of injec-
tion valve -N108
♦Commencement of injec-
tion valve -N108 worn
♦Poor performance at higher
revs
♦Engine difficult to start
♦Increased emission levels
♦Poor performance at higher
revs
♦Fault 00542 Needle lift
sender implausible signal
may be stored
♦Engine clatters when idling
as commencement of injec-
tion constantly ”advanced”
♦Several faults may be
stored
♦No constant commence-
ment of injection possible
at ”Basic setting” (display
block 2 varies over more
than 10 readouts)
♦Irregular engine running,
poor performance
- Test and set commence-
ment of injection
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Test injection timing con-
trol range
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Erase fault memory, con-
tinue checking vehicle
- Check fuel system
- Test commencement of
injection valve
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Test fuse
- Replace commencement
of injection valve
------------
------------
ProCarManuals.com
OCTAV1ASelf-Diagnosis 01
dition 01.04
S00.5122.55.20
Readout V.A.G 1552
Fault number
old
00553
Air mass meter
-G70
Implausible sig-
nal
Line interrup-
tion/short-circuit
to earth
Short-circuit to
positive
Supply voltage
00575
Intake manifold
pressure
Control differ-
ence
or
Charge pressure
Control differ-
ence
new
16485
17552
17553
17554
17958
Possible cause of fault
♦he engine was stalled
(within the last 50 engine
starts)
♦Battery weak
♦Sporadic line interruption
(cable parting) of needle
lift sender -G80
♦Air filter blocked
♦Incorrect vacuum piping of
exhaust gas recirculation
or mechanical exhaust
gas recirculation valve
constantly open
♦Air mass meter defective
♦-G70 defective
♦Line interruption or short-
circuit to earth
♦-G70 defective
♦Line interruption or short-
circuit to positive
♦Line interruption or short
circuit
♦Hoses mixed up, not fit-
ted, blocked, leaking
♦Pressure unit of turbo-
charger defective
♦Charge pressure control
solenoid valve -N75 de-
fective
Possible effects
♦Reduced performance
♦Air mass meter constantly
display in measured value
block
♦Misfiring, jerking
♦Possible fault 00542 nee-
dle lift sender, input open
or Interruption/short-circuit
to positive
♦Irregular engine running,
Poor performance
♦Poor performance, jerking
♦Reduced performance
♦Possible black smoke
when accelerating from
low engine speeds
♦Sudden decrease of per-
formance
♦Reduced performance
Rectifying fault
- Erase fault memory, ob-
serve vehicle again
- Check battery
- Check needle hub sender
⇒1.9l/66 kW ( DI) Engine,
Fuel Injection and Glow
Plug System
- Check intake system
- Check vacuum piping
⇒ page 23-9
- Check air mass meter
⇒ page 23-10
- Check charge pressure
⇒ page 23-4
- Check charge pressure
hose ⇒ page 23-9
------------
01-13 -------------
ProCarManuals.com
OCTAVIA
01 Self-Diagnosis
Edition 01.02
S00.5122.53.20
Readout on V.A.G 1552
Fault number
♦Open circuit in wiring be-
tween speedometer sender
-G22 and dash panel insert
♦-G22 faulty
♦Speedometer -G21 faulty
♦Open circuit in wiring be-
tween dash panel insert
and engine control unit
♦Short circuit to positive
♦Open circuit in wiring
♦Bulb faulty
♦Short circuit to earth
♦Diesel direct injection sys-
tem relay - 322 jamming
♦Diesel direct injection sys-
tem relay - 322 faulty
♦E45 faulty
♦Open circuit or short cir-
cuit
new
16885
17948
18024
18025
1800
-
Possible cause of fault Possible effects Rectifying fault
old
00625
Speed signal
implausible sig-
nal
or
Vehicle speed signal
implausible sig-
nal
Vehicle speed signal
signal too large
00626
Glow period warn-
ing light -K29
short to positive
open circuit/short
to earth
00668
El. voltage terminal
30
implausible sig-
nal
00671
CCS switch -E45
undefined switch
status
------------
01-14 ------------
♦CCS not operating 1)
♦AC not operation
♦Possible load change jolts
♦Speed indication not cor-
rect
♦Glow period warning lamp
not operating
♦Glow period warning lamp
not operating
♦Glow period warning lamp
illuminated constantly
♦Engine does not start
(safety shutoff)
♦Cruise control system is
switched off
- Test vehicle speed signal
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Test speedometer sender
⇒
Electrical System; Repair
Group 90
- Test glow period warning
light
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Test voltage supply of die-
sel direct injection system
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
- Test cruise control system
⇒
1.9-ltr./66 kW (TDI) En-
gine, Fuel Injection and
Glow Plug System
ProCarManuals.com
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