Post on 06-Apr-2018
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Service
Workshop Manual
OCTAVIA
Service Department. Technical Information
S00.5126.50.20 Edition 07.99
1.4-ltr./44 kW Engine, Simos 3PB Fuel
Injection and Ignition System
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The Service Manual is intended only for use within the koda Organisation;it is not permitted to pass it onto third persons. 1999 KODA AUTO a. s.
Printed in CR
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Service
List of Supplements forOCTAVIA Workshop Manual Edition: 06.00
1.4-ltr./44 kW Engine, Simos 3PB Fuel Injection and IgnitionSystem
Replaces List of Supplements - Edition: 07.99
Supple- Edition Subject Article Numberment
07.99 Basic Edition Workshop Manual S00.5126.50.20
1 06.00 Supplement to Basic Edition S00.5126.51.20
2
3
4
5
6
7
89
10
11
12
13
14
15
1617
18
19
20
Contents next page.
The Workshop Manual is intended only for use withinthe koda Organisation; it is not permitted to pass iton to third parties.
2000 KODA AUTO a. s.
Printed in CR
S00.5126.51.20
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Edition 07.99S00.5126.50.20
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OCTAVIA ServiceContens
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 .............................................................................................................. 01-30- Reading measured value block ................................................................................................ 01-32- Reading measured value block: display groups 000 to 010 ..................................................... 01-33- Reading measured value block: display groups 011 to 055 ..................................................... 01-37
24 Fuel Formation/Fuel Injection Page
Servicing Fuel Injection System ................................................................................................ 24-1
- Safety precautions .................................................................................................................... 24-1- Rules for cleanliness ................................................................................................................ 24-2- Technical data .......................................................................................................................... 24-2- Survey of fitting locations ......................................................................................................... 24-3- General information on fuel injection system ........................................................................... 24-7- Removing and installing parts of the fuel injection system....................................................... 24-8- Disassembling and assembling fuel rail and injectors ............................................................. 24-10- Disassembling and assembling intake manifold ...................................................................... 24-10- Disassembling and assembling air filter ................................................................................... 24-11- Testing cables and components with test box V.A.G 1598/31 ................................................. 24-12- Replacing engine control unit ................................................................................................... 24-14- Testing idling speed .................................................................................................................. 24-15- Testing operating states of engine............................................................................................ 24-17
- Testing fuel pressure regulator and holding pressure .............................................................. 24-19- Testing intake system for leaks (unmetered air) ...................................................................... 24-22- Testing injectors........................................................................................................................ 24-23- Testing injected quantity, leaktightness and spray pattern of injectors..................................... 24-25- Testing fuel pump relay -J17 and actuation.............................................................................. 24-27- Testing intake manifold pressure sender -G71 ........................................................................ 24-30- Testing intake manifold temperature sender -G72 ................................................................... 24-31- Testing coolant temperature sender -G62................................................................................ 24-34- Testing voltage supply for control unit ...................................................................................... 24-38- Adapting engine electronics control unit to electronic immobiliser ........................................... 24-39
Testing lambda control ............................................................................................................... 24-41- Operation of lambda control ..................................................................................................... 24-41- Testing lambda probe heater.................................................................................................... 24-47
Testing fuel tank ventilation ....................................................................................................... 24-49- Testing solenoid valve 1 for activated charcoal filter ................................................................ 24-49
Testing electronic power control (electronic throttle) ............................................................. 24-52- Operation of electronic throttle system..................................................................................... 24-52- Meaning of EPC warning lamp (electronic throttle control fault lamp) in dash panel insert ..... 24-53- Testing electronic throttle control fault lamp -K132 .................................................................. 24-54- Testing throttle valve control unit -J338 .................................................................................... 24-56- Conducting adaptation of throttle valve control unit ................................................................. 24-56- Testing angle senders for throttle valve drive ........................................................................... 24-59- Testing accelerator pedal position sender ................................................................................ 24-62
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Testing additional signals .......................................................................................................... 24-65- Testing engine speed signal ..................................................................................................... 24-65- Testing fuel consumption signal for multifunction display......................................................... 24-65- Testing road speed signal......................................................................................................... 24-65- Testing brake light switch -F and brake pedal switch -F47....................................................... 24-67- Testing clutch pedal switch -F36- ............................................................................................. 24-71- Testing power steering pressure switch -F88-.......................................................................... 24-73- Testing databus (CAN bus) ...................................................................................................... 24-75
28 Ignition System Page
Testing ignition system .............................................................................................................. 28-1- General information on ignition system .................................................................................... 28-1- Safety precautions .................................................................................................................... 28-1- Setting data of spark plugs....................................................................................................... 28-2- Removing and installing ignition system .................................................................................. 28-3- Testing ignition coils with power output stage .......................................................................... 28-4- Testing camshaft position sensor -G163 .................................................................................. 28-6- Testing knock sensor -G61 ...................................................................................................... 28-8- Testing engine speed sender -G28 .......................................................................................... 28-10
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OCTAVIA ServiceContents
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 .............................................................................................................. 01-30- Reading measured value block ................................................................................................ 01-32- Reading measured value block: display groups 000 to 010 ..................................................... 01-33- Reading measured value block: display groups 011 to 055 ..................................................... 01-37
24 Fuel Formation/Fuel Injection Page
Servicing Fuel Injection System ................................................................................................ 24-1
- Safety precautions .................................................................................................................... 24-1- Rules for cleanliness ................................................................................................................ 24-2- Technical data .......................................................................................................................... 24-2- Survey of fitting locations ......................................................................................................... 24-3- General information on fuel injection system ........................................................................... 24-7- Removing and installing parts of the fuel injection system....................................................... 24-8- Disassembling and assembling fuel rail and injectors ............................................................. 24-10- Disassembling and assembling intake manifold ...................................................................... 24-10- Disassembling and assembling air filter ................................................................................... 24-11- Testing cables and components with test box V.A.G 1598/31 ................................................. 24-12- Replacing engine control unit ................................................................................................... 24-14- Testing idling speed .................................................................................................................. 24-15- Testing operating states of engine............................................................................................ 24-17
- Testing fuel pressure regulator and holding pressure .............................................................. 24-19- Testing intake system for leaks (unmetered air) ...................................................................... 24-22- Testing injectors........................................................................................................................ 24-23- Testing injected quantity, leaktightness and spray pattern of injectors..................................... 24-25- Testing fuel pump relay -J17 and actuation.............................................................................. 24-27- Testing intake manifold pressure sender (G71) ....................................................................... 24-30- Testing intake manifold temperature sender (G72) .................................................................. 24-31- Testing coolant temperature sender (G62)............................................................................... 24-35- Testing voltage supply for control unit ...................................................................................... 24-38- Adapting engine electronics control unit to electronic immobiliser ........................................... 24-39
Testing lambda control ............................................................................................................... 24-41- Operation of lambda control ..................................................................................................... 24-41- Testing lambda probe heater.................................................................................................... 24-47
Testing fuel tank ventilation ....................................................................................................... 24-49- Testing solenoid valve 1 for activated charcoal filter ................................................................ 24-49
Testing electronic power control (electronic throttle) ............................................................. 24-52- Operation of electronic throttle system..................................................................................... 24-52- Meaning of EPC warning lamp (electronic throttle control fault lamp) in dash panel insert ..... 24-53- Testing electronic throttle control fault lamp -K132 .................................................................. 24-54- Testing throttle valve control unit -J338- ................................................................................... 24-56- Conducting adaptation of throttle valve control unit ................................................................. 24-56- Testing angle senders for throttle valve drive ........................................................................... 24-59- Testing accelerator pedal position sender ................................................................................ 24-62
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OCTAVIA Self-Diagnosis 01
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S00.5126.50.20
------------ 01-1 ------------
Self-diagnosis
Note:
Self-diagnosis monitors only a part of the fuelinjection and ignition system.
Features of self-diagnosis
The Simos 3PB control unit is equipped with afault memory. The fault memory is designed asa permanent memory.
If faults occur at the monitored sensors or com-ponents, these are stored in the fault memorywith an indication of the fault type.
Faults which occur only occasionally (sporadi-cally), appear in the display with the addition /SP. The cause of a sporadic fault may be, forexample, a loose contact or a temporary open
circuit in the wiring. If a sporadic fault no longeroccurs within 40 engine starts, it is erased fromthe fault memory.
These stored faults can be read with the vehi-cle system tester V.A.G 1552 or with the faultreader V.A.G 1551 page 01-4.
After rectifying the fault or faults, the faultmemory must be erased page 01-4.
Note:
The description which follows relates only to thevehicle system tester V.A.G 1552 using the pro-gramme card 5.0 or higher.
Technical data of self-diagnosis
Interrogating control unit version
The control unit version is displayed when thevehicle system tester V.A.G 1552 is connectedand the engine electronics control unit selected page 01-2.
Functions available when using vehicle sys-tem tester V.A.G 1552
Please refer to the table which follows for theconditions which must exist to allow you to se-lect the desired functions.
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OCTAVIA01 Self-Diagnosis
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Function Requirement
Ignition on Engineidling
02 Interrogating fault yes1) yesmemory
03 Final control diagnosis yes no
04 Initiating basic setting yes2) no
05 Erasing fault memory yes yes
06 Ending output yes yes
08 Reading measured yes yesvalue block
1) Only if engine does not start (starter mustbe operated for at least 6 seconds).
2) Must be carried out after completing thefollowing operations:Replacing engine control unit, throttle valvecontrol unit or engine, or disconnectingbattery.
Connecting vehicle system tester
V.A.G 1552 and selecting engine
electronics control unit
Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable
V.A.G 1551/3
Test requirements
l Battery voltage at least 11 V
l Fuses according to up-to-date current flowdiagram o.k.
l Earth connections at front of clutch housingand at cylinder head o.k.
------------ 01-2 ------------
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OCTAVIA Self-Diagnosis 01
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047906033B 1.4 l SIMOS 3PB 00HSSC01 Coding 00001 WSC 00000
Test of vehicle systems HELPSelect function XX
Test of vehicle systems HELPEnter address word XX
Procedure
K - Connect vehicle system tester V.A.G 1552with cable V.A.G 1551/3.
After connecting the vehicle system tester:
- Either, depending on the function desired,switch on the ignition
orstart the engine page 01-1, table of Avail-able Functions.
Notes:
If the readout which appears in the displaydoes not correspond to the procedure:
Operating instructions of vehicle systemtester
If Error in data transmission! is displayedbecause of an incorrect entry, unplug cableat fault reader, plug in again and repeat thesesteps.
KReadout in display:
Note:
Operate the vehicle system by referring to thereadout in the display.
- Press keys 0 and 1 for the address wordEngine electronics and confirm the engine
with the key Q.
K The control unit identification appears in the dis-play (example):
047906033B = Part No. of control unit
1.4 l = Displacement of engine
SIMOS 3PB = System designation
HS = Manual gearbox
SC01 = Software number
- Press the key.
KReadout in display:
- For the further procedureRepair Descrip-tions.
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OCTAVIA01 Self-Diagnosis
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Test of vehicle systems HELP
Select function XX
Interrogating and erasing fault
memory
Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable
V.A.G 1551/3
Procedure
- Connect vehicle system tester V.A.G 1552and select engine electronics (address word01); engine idling for this step page 01-2.
Only if engine does not start:
- Switch on ignition.
KReadout in display:
- Press keys 0 and 2 for the function Interro-gate fault memory and confirm the entry withthe key Q.
K The number of stored faults or No fault recog-nized! appears in the display.
If one or several faults are stored:
The stored faults are displayed one after theother.
KReadout in display:
- Press keys 0 and 5 for the function Erasefault memory and confirm the entry with thekey Q.
Note:
If you have switched off the ignition betweenInterrogating fault memory and Erasing faultmemory, the fault memory is not erased.
Test of vehicle systems HELPSelect function XX
X faults recognized!
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OCTAVIA Self-Diagnosis 01
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KReadout in display:
- Press the key.
- Press keys 0 and 6 for the function End out-put and confirm the entry with the key Q.
- Rectify the faults displayed by referring to thefault table page 01-6.
- After rectifying the faults, it is then neces-sary to carry out a road test.
The following operating conditions must bemet during this road test:
The coolant temperature must rise to mo-re than 80 C.
Once this temperature is reached, the fol-lowing operating states must be achievedseveral times:
Idling speedPart loadFull load
Fuel shut-off on overrun.
At full throttle, the engine speed must riseto more than 3500 rpm page 24-17.
- Once again, interrogate the fault memory ofthe control unit.
If no fault is stored:
- Press the key.
KReadout in display:
- Press keys 0 and 6 for the function Endoutput and confirm the entry with the key Q.
Test of vehicle systems Fault memory is erased!
Test of vehicle systems HELPSelect function XX
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OCTAVIA01 Self-Diagnosis
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Fault table
Notes:
The fault table is arranged according to the 5-digit faultcode shown on the left.
The SAE code (e.g. P0107) which is positioned on theright next to the fault code, should be ignored (appliesat present only to USA).
Explanations regarding fault types (e.g. open or shortcircuit to earth):
Operating instructions of vehicle system tester
If components are shown as faulty:Test cables and plug connections to these components,and also earth cables of the system according to thecurrent flow diagram. Replace component only if nofault is also found in this case. This applies in particularto faults which are shown as sporadic (SP).
Readout on V.A.G 1552
16496
Intake air temperaturesender -G72
Signal too small
16497
Intake air temperaturesender -G72
Signal too large
16500
Coolant temperature sender-G62
Implausible signal
Possible cause of fault
Short circuit to earth Sender -G72 faulty
Short circuit to positive Sender -G72 faulty
Coolant temperaturesender -G62 supplyingimplausible signal be-cause of loose contact, orcorrosion caused bymoisture in connector
Signal input in enginecontrol unit faulty (controlunit faulty)
Rectifying fault
- Read measured valueblock, display group 004,display block 4 page 01-36.
- Test intake air temperaturesender page 24-31.
- Read measured valueblock, display group 004,
display block 4 page 01-36.
- Test intake air temperaturesender page 24-31.
- Read measured valueblock, display group 004,display block 3 page 01-36.
- Test coolant temperaturesender page 24-35.
- Replace engine controlunit page 24-14.
Possible effects
Emergency mode, controlunit operating with substi-tute temperature
Emergency mode, controlunit operating with substi-
tute temperature
Cold start problems at verylow temperatures
Poor driving characteristicsin warming-up phase
Increased fuel consump-tion
Increased emission levels
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OCTAVIA Self-Diagnosis 01
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Readout on V.A.G 1552
16501
Coolant temperature sender-G62
Signal too small
16502
Coolant temperature sender-G62
Signal too large
16514
Bank 1, probe 1
Electrical fault in circuit
16515
Bank 1, probe 1
Voltage too small
Possible cause of fault
Short circuit to earth Sender -G62 faulty
Short circuit to positive Sender -G62 faulty
Open circuit in wiring orshort circuit to earth
Lambda probe faulty
Short circuit of lambdaprobe signal cable toearth or to screening
Short circuit of lambdaprobe signal cable toearth or to screening
Lambda probe faulty
Possible effects
Cold start problems at verylow temperatures
Poor driving characteristicsin warming-up phase
Increased fuel consump-tion
Increased emission levels
Cold start problems at verylow temperatures
Poor driving characteristicsin warming-up phase
Increased fuel consump-tion
Increased emission levels
Lambda closed-loop con-trol switches to open-loop
Poor idling Increased emission levels
Increased fuel consump-tion
Lambda closed-loop con-trol switches to open-loop
Poor idling
Emission levels not o.k.
Increased fuel consump-tion
Rectifying fault
- Read measured valueblock, display group 004,display block 3 page 01-36.
- Test coolant temperaturesender page 24-35.
- Read measured valueblock, display group 004,display block 3 page 01-36.
- Test coolant temperaturesender page 24-35.
- Rectify short circuit oropen circuit in wiring
Current Flow Diagrams,Fault Finding and Fitting
Locations binder
- Test lambda control page 24-41.
- Rectify short circuit oropen circuit in wiring
Current Flow Diagrams,Fault Finding and FittingLocations binder
- Test lambda control page 24-41.
- Read measured valueblock, display group 030 page 01-38.
- Read measured valueblock, display group 031 page 01-39.
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OCTAVIA01 Self-Diagnosis
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Readout on V.A.G 1552
16516
Bank 1, probe 1
Voltage too large
16517
Bank 1, probe 1
Signal too slow
16518
Bank 1, probe 1
No activity
Possible cause of fault
Short circuit of signal ca-
ble to positive
Lambda probe faulty
Lambda probe faulty
Lambda probe faulty(dirty)
Open circuit in wiring be-tween probe heater and
engine control unit
Lambda probe heater notoperating
Possible effects
Lambda closed-loop con-
trol switches to open-loop
Poor idling
Lambda closed-loop con-trol switches to open-loop
Poor idling Emission levels not o.k. Increased fuel consump-
tion
Increased fuel consump-tion
Emission levels not o.k.
Carbon deposits on sparkplugs
Rectifying fault
- Rectify short circuit or
open circuit in wiring Current Flow Diagrams,
Fault Finding and FittingLocations binder
- Test lambda control page 24-41.
- Test lambda control page 24-41.
- Read measured valueblock, display group 030 page 01-38.
- Read measured valueblock, display group 031
page 01-39.
- Test lambda probe heater page 24-47.
Note on fault codes 16500 - 16502:
As soon as one of the faults is recognised, the control unituses a substitute value from the model map stored in thecontrol unit.
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OCTAVIA Self-Diagnosis 01
Edition 06.00
S00.5126.51.20
------------ 01-9 ------------
Readout on V.A.G 1552
16554
Bank 1, fuel metering sys-tem
Malfunction
16555
Bank 1, fuel metering sys-tem
System too lean
Possible cause of fault
Fuel pressure regulatorfaulty
Injectors faulty
Fuel system faulty
Lambda probe faulty
Possible effects
Engine does not start Increased emission levels Poor starting characteris-
tics
Lambda closed-loop con-trol switches to open-loop
Poor idling
Emission levels not o.k.
Increased fuel consump-tion
Rectifying fault
- Test fuel pressure regula-tor and holding pressure page 24-19.
- Test injectors page 24-23.
- Test injected quantity andleaktightness page 24-25.
- Test fuel pump: 1.4-ltr./44 kW Engine, Me-
chanical Components;Repair Group 20; Testingfuel pump
- Inspect intake system for
leaks page 24-22.- Test exhaust system for
leaks: 1.4-ltr./44 kW Engine, Me-
chanical Components;Repair Group 26; Remov-ing and installing parts ofexhaust system
- Inspect vacuum lines forleaks.
- Test fuel pressure regula-tor and holding pressure page 24-19.
- Test lambda control page 24-41.
- Read measured valueblock, display group 030 page 01-38.
- Read measured valueblock, display group 031 page 01-39.
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OCTAVIA01 Self-Diagnosis
Edition 06.00
S00.5126.51.20
------------ 01-10 ------------
Readout on V.A.G 1552
16556
Bank 1, fuel metering sys-tem
System too rich
16705
Engine speed sender -G28
Implausible signal
16706
Engine speed sender -G28
No signal
16711
Knock sensor 1 -G61
Signal too small
16712
Knock sensor 1 -G61
Signal too large
Possible cause of fault
Fuel system faulty
Lambda probe faulty
Engine speed sender-G28 loose
Signal cable has open cir-cuit or short circuit to earthor to positive
Earth cable has open cir-cuit or short circuit to posi-tive
-G28 loose, or faulty Open circuit to screening
of -G28 Signal input in engine con-
trol unit faulty (control unitfaulty)
Knock sensor faulty
Short circuit to earth
Knock sensor faulty Short circuit to earth
Possible effects
Lambda closed-loop con-trol switches to open-loop
Poor idling
Engine misfires
Engine does not start
Engine cuts out
High fuel consumption
Reduced power
High fuel consumption Reduced power
Rectifying fault
- Test fuel pressure regula-tor and holding pressure page 24-19.
- Test lambda control page 24-41.
- Read measured valueblock, display group 030 page 01-38.
- Test lambda control page 24-41.
- Test engine speed sender-G28 page 28-10.
- Rectify open circuit in wir-ing or short circuit.
Current Flow Diagrams,Fault Finding and FittingLocations binder
- Test engine speed sender-G28 page 28-10.- Replace engine control
unit page 24-14.
- Test knock sensor -G61
page 28-8.
- Test knock sensor -G68 page 28-8.
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OCTAVIA Self-Diagnosis 01
Edition 06.00
S00.5126.51.20
------------ 01-11 ------------
Readout on V.A.G 1552
16719
Engine speed sender -G28
Malfunction
16725
Camshaft position sensor=> sender -G40
Implausible signal
16726
Camshaft position sensor=> sender -G40
Signal too small
Possible cause of fault
Short circuit of lambda
probe signal wire to earthor to screening
Earth cable has open cir-cuit or short circuit to posi-tive
-G28 loose, or faulty Open circuit to screening
of -G28 Signal input in engine con-
trol unit faulty (control unitfaulty)
Voltage supply or earthsupply for camshaft posi-tion sensor -G1631) faulty
-G163 faulty Signal input in engine con-
trol unit faulty (control unitfaulty)
Open circuit or short circuitto earth or to positive insignal cable between-G163 and engine controlunit
Timing chain stretched(engines with high mile-age)
-G1631) faulty
Large contact resistancesin connectors (corrosion)
Possible effects
Engine does not start
Engine cuts out
Engine does not rev up tomaximum speed
Poor performance
Start problems
Valve timing loud, reducedengine output
Engine does not rev up tomaximum speed
Poor performance
Start problems
Rectifying fault
- Rectify open circuit in wir-
ing or short circuit. Current Flow Diagrams,
Fault Finding and FittingLocations binder
- Test engine speed sender-G28 page 28-10.
- Replace engine controlunit page 24-14.
- Test camshaft position sen-sor -G163 page 28-6
- Rectify open circuit in wir-ing or short circuit accord-ing to current flow diagram
Current Flow Diagrams,Fault Finding and FittingLocations binder
- Read measured valueblock, display group 012;check readouts in displayblocks 3 and 4 page 01-37.
- Test camshaft positionsensor -G163 page 28-6.
- Test cable connection orwiring to -G163
Current Flow Diagrams,Fault Finding and FittingLocations binder
1) The camshaft position sensor -G163 is identical with the Hall sender -G40.
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OCTAVIA01 Self-Diagnosis
Edition 06.00
S00.5126.51.20
------------ 01-12 ------------
Readout on V.A.G 1552
16825
Tank vent system
Flow faulty
16885
Vehicle speed signal
Implausible signal
Possible cause of fault
-N80 faulty
Open circuit in wiring orshort circuit
Vehicle speed senderfaulty
Open circuit in wiring orshort circuit between vehi-cle speed sender andspeedometer
Open circuit in wiring orshort circuit between dashpanel insert and enginecontrol unit
Possible effects
Irregular idling
Smell of fuel
Brief variation betweenidling speed and specifiedspeed
Poor load change charac-teristics
Malfunction in systemswhich use vehicle speedsignal
Rectifying fault
- Test activated charcoal fil-
ter solenoid valve page01-30, Final control diag-nosis
1.4-ltr./44 kW Engine, Me-chanical Components;Repair Group 20; Remov-ing and installing acti-vated charcoal filter
- Inspect hoses and connec-tion pipes from fuel tankup to throttle valve controlunit.
1.4-ltr./44 kW Engine, Me-chanical Components;
Repair Group 20; Remov-ing and installing fuel tankwith attached parts andfuel filter
- Rectify open circuit in wir-ing or short circuit accord-ing to CFD
Current Flow Diagrams,Fault Finding and FittingLocations binder
- Read measured valueblock, display group 005,display block 3 page 01-36.
- Rectify open circuit in wir-ing or short circuit.
Current Flow Diagrams,Fault Finding and FittingLocations binder
- Test vehicle speed signal page 24-65.
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OCTAVIA Self-Diagnosis 01
Edition 06.00
S00.5126.51.20
------------ 01-13 ------------
Readout on V.A.G 1552
Idling speed
Speed below set value
Idling speed
Speed above set value
16955
!
Implausible signal
"
#
$
%
&
'
No message
(
)
unit%
0
$
)
unit%
0
$
1
&
'
of fault
Throttle valve positioner
jamming
Air filter blocked
Unmetered air down-stream of throttle valve
Injector faulty
Fuel pressure regulatorfaulty
Brake light switch faulty
Open circuit in wiring orshort circuit to positive orto earth between brake
light switch and enginecontrol unit
Open circuit in datalines toABS control unit
Engine control unit faulty
Engine control unit faulty
1
&
0 0
Poor driving characteris-
tics
Increased fuel consump-tion
Smell of fuel
Brake light does not comeon
Variations in engine speedduring brake application
Poor driving characteris-tics
Variations in engine speedwhen ABS activated
Engine does not start
Engine does not start
2
0
3
0
'
- Test throttle valve control
unit page 24-56.
- Inspect intake system forleaks (unmetered air) page 24-22.
- Test throttle valve controlunit page 24-56.
- Test injectors page 24-23.
- Replace fuel pressureregulator.
- Test brake light switch -F page 24-67.
- Rectify open circuit in wir-ing or short circuit accord-ing to current flow diagram
Current Flow Diagrams,Fault Finding and FittingLocations binder
- Test databus page 24-75.
- Replace engine control
unit page 24-14.
- Replace engine controlunit page 24-14.
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OCTAVIA01 Self-Diagnosis
Edition 06.00
S00.5126.51.20
------------
------------
Readout on V.A.G 1552
unit
!
"
#
$
&
'
eating
)
Short to positive
!
1
"
#
$
&
'
eating
)
Insufficient capacity
ossible #
)
0
of fault
Engine control unit faulty
Short circuit to positive incable from engine controlunit to lambda probe
Output stage in engine
control unit faulty (enginecontrol unit faulty)
Lambda probe faulty
Fuel pump relay or actua-tion of fuel pump relayfaulty
Open circuit in cable from
engine control unit tolambda probe
Output stage in enginecontrol unit faulty (enginecontrol unit faulty)
Lambda probe faulty
Fuel pump relay or actua-
tion of fuel pump relayfaulty
ossible
0
Engine does not start
Irregular idling Emission levels not o.k.
Irregular idling
Emission levels not o.k.
1
2
3
#
)
- Replace engine controlunit page 24-14.
- Test lambda probe heater page 24-47.
- Rectify short circuit ac-cording to CFD
Current Flow Diagrams,Fault Finding and FittingLocations binder
- Replace engine control
unit
page 24-14.
- Replace lambda probe.
- Test fuel pump relay andactuation page 24-27.
- Test lambda probe heater
page 24-47.- Rectify open circuit ac-
cording to CFD Current Flow Diagrams,
Fault Finding and FittingLocations binder
- Replace engine controlunit page 24-14.
- Replace lambda probe.
- Test fuel pump relay and
actuation
page 24-27.
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OCTAVIA Self-Diagnosis 01
Edition 06.00
S00.5126.51.20
------------
------------
Readout on V.A.G 1552
" #
#
%
Short circuit to earth
&
" #
#
%
Open circuit
& '
(
) )
#
Implausible value
0
1 1
#
%
1
of fault
Short circuit to earth in ca-ble from engine controlunit to lambda probe
Output stage in enginecontrol unit faulty (enginecontrol unit faulty)
Lambda probe faulty
Open circuit in wiring fromengine control unit tolambda probe
Output stage in engine
control unit faulty (enginecontrol unit faulty)
Lambda probe faulty
Leak in intake system
0
1 1
3 3
#
1
Irregular idling Emission levels not o.k.
Irregular idling Emission levels not o.k.
Reduced output
4
#
3
5
"
3
%
- Test lambda probe heater page 24-47.
- Replace engine controlunit page 24-14.
- Replace lambda probe. 1.4-ltr./44 kW Engine, Me-
chanical Components;Repair Group 26; Remov-ing and installing parts ofexhaust system
- Test lambda probe heater page 24-47.
- Rectify open circuit in wir-ing.
Current Flow Diagrams,Fault Finding and FittingLocations binder
- Replace engine control
unit page 24-14.
- Replace lambda probe. 1.4-ltr./44 kW Engine,Mechanical Components;Repair Group 26; Remov-ing and installing parts ofexhaust system
- Test intake system forleaks (unmetered air) page 24-22.
- Erase fault memory page 01-4 and conductroad test.
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OCTAVIA01 Self-Diagnosis
Edition 06.00
S00.5126.51.20
------------
------------
Readout on V.A.G 1552
! " # #
$
"
#
"
&
Short to positive
'
! " # #
$
"
#
"
&
(
) 0 1
2
3
4
5 6
7
to0 8 6
7
4
9
! "
$
"
#
"
&
@
Short to0 8 6
7
4
PossibleA
$
#
of fault
B8
C
0
4
8 3
short E6
E
G
7
topositive
H
I
P
Q R
8
G
7
S
(
) 0 1
E
6
E
G
7
in T6 1 U
B
8
C
0
4
8 3
short E6
E
G
7
to0 8 6
7
4
HI
P
Q R
8
G
7
S
Short E6
E
G
7
to0 8 6
7
4
in E8
H
C
0
E
5 1 1 0
E
7
5 1
C
0
7
T
0 0 1
1
7
8
V
0 W 8 1
R
5
X
7
0 W ) 0 6 8
H
7
G
6 0 3 0 1
X
0 6
H
I
P
Y
8 1
X
0 1
H
U 1 0
E
5 1
7
6 5
G
1
7
HI
P
Y R
8
G
7
S
`
U 1 8 1 )
G
7
in0 1 U 1 0
E
5 1
7
6 5
G
1
7
R
8
G
7
S
a
E
5 1
7
6 5
G
1
7
R
8
G
7
S
b
HI
P
Y R
8
G
7
S
c
8
G
7
in0 8 6
7
4
3
G
) )
S
toH
I
P
Y
`U 1 8 1 )
G
7
in0 1 U 1 0
E
5 1
7
6 5
G
1
7
R
8
G
7
S
a
E
5 1
7
6 5
G
1
7
R
8
G
7
S
b
Possible
A
#
1
E
6 0 8 3 0
X
0 W 3 3 5 1 0
e
0 3
f
5 5 6
7
4
6 5
7 7
0
response
g
8 6
X
5 8
X
E
4
8 1 U 0 5
7
3
1
E
6 0 8 3 0
X
0 W 3 3 5 1 0
e
0 3
f
5 5 6
7
4
6 5
7 7
0
response
g
8 6
X
5 8
X
E
4
8 1 U 0 5
7
3
iW 0 6 U 0 1
E
S
W 5
X
0
p
0 1 U 1 0
E
5 1
7
6 5
G
1
7
5 ) 0 6 8
7
0 3
T
7
4
3
G
C
3
7 7
G
7
0
7
0 W ) 0 6 8
7
G
6 0
in1 0
T
7
4
E
5 5 8 1
7 7
0 W ) 0 6 8
H
7
G
6 0
q
A
r
s
$
H
t
est1
7
8
V
0 W 8 1
R
5
X
) 6 0 3
H
3
G
6 0 3 0 1
X
0 6
H
I
P
Q
) 8 U 0
Y u
H
v w
H
t
est1
7
8
V
0 3
S
3
7
0 W
R
5 6
0 8
V
3
a
G
1 W 0
7
0 6 0
X
8 6
b
) 8 U 0
Y u
H
Y Y
H
t
est1
7
8
V
0 W 8 1
R
5
X
) 6 0 3
H
3
G
6 0 3 0 1
X
0 6
H
I
P
Q
) 8 U 0
Y u
H
v w
H
t
est1
7
8
V
0 3
S
3
7
0 W
R
5 6
0 8
V
3
a
G
1 W 0
7
0 6 0
X
8 6
b
) 8 U 0
Y u
H
Y Y
H
y
0 8
X
W 0 8 3
G
6 0
X
e
8
G
0
C
5
E
V
p
X
3 ) 8
S
U 6 5
G
)
w w u
p
X
3 ) 8
S
C
5
E
V
) 8 U 0
w Q
H
v
H
t
est1
7
8
V
0 W 8 1
R
5
X
7
0 W
H
) 0 6 8
7
G
6 0 3 0 1
X
0 6
H
I
P
Y
) 8 U 0
Y u
H
v Q
H
y
0 ) 8
E
0 0 1 U 1 0
E
5 1
7
6 5
G
1
7
) 8 U 0
Y u
H
Q u
H
t
est1
7
8
V
0 W 8 1
R
5
X
7
0 W
H
) 0 6 8
7
G
6 0 3 0 1
X
0 6
H
I
P
Y
) 8 U 0
Y u
H
v Q
H
y
0 ) 8
E
0 0 1 U 1 0
E
5 1
7
6 5
G
1
7
) 8 U 0
Y u
H
Q u
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OCTAVIA Self-Diagnosis 01
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S00.5126.51.20
------------
------------
Readout on V.A.G 1552
17569
-G72
Open/short to positive
17579
Angle
2
TV
" # $ $
Implausible signal
#
% &
$ '
Angle
2
(
" # $ $
Signal too small
)
0
1
of fault
Open circuit or short cir-cuit to positive in cableconnection between in-take manifold temperaturesender -G72 and enginecontrol unit
-G72 faulty Fault in earth supply to
-G72
Signal input in enginecontrol unit faulty (controlunit faulty)
-G188 faulty or loose con-tact in plug connection forthrottle valve control unit-J338
Signal input in enginecontrol unit faulty (enginecontrol unit faulty)
Incorrect connector as-signment
Open circuit or short cir-cuit to earth in signal ca-ble from -G188 to enginecontrol unit
)
0
1
Emergency mode, enginecontrol unit operates withsubstitute temperature inline with coolant tempera-ture
Engine runs in emergencymode
Reduced output Irregular idling
Engine runs in emergencymode
Altered idling speed
2
1
3
4
- Read measured valueblock, display group 004,display block 4 page 01-36.
- Test intake manifold tem-perature sender -G72 page 24-31.
- Replace engine controlunit page 01-36.
- Test throttle valve controlunit page 24-56.
- Replace engine controlunit page 24-14.
- Test throttle valve controlunit page 24-56.
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OCTAVIA01 Self-Diagnosis
Edition 06.00
S00.5126.51.20
------------
------------
Readout on V.A.G 1552
Angle
2
"
Signal too large
# $
&
'
'
(
0 1 2
Short to positive
3
4
cause of fault
Open circuit in earth cablefrom -G188 to engine con-trol unit
-N30 faulty Cable has short circuit to
positive
3
4
effects
Engine runs in emergencymode
Cold start problems Cold idling problems
Increased emission levels Poor start characteristics Poor driving characteris-
tics Poor throttle response Irregular idling
5
'
(
6
7
- Test throttle valve controlunit page 24-56.
- Test injectors N30...N33 page 24-23.
# $ $
&
'
'
(
$ 0 1
Short to positive
# $ 1
&
'
'
(
1 0 1 $
Short to positive
# $ 8
&
'
'
(
8 0 1 1
Short to positive
Fault code 17621, cyl. 1
Fault code 17621, cyl. 1
Fault code 17621, cyl. 1
# 1 1
&
'
'
(
0 1 2
Short to earth -N30 faulty Cable has short circuit to
earth
Increased emission levels Poor start characteristics Poor driving characteris-
tics Poor throttle response Irregular idling
- Test injectors N30...N33 page 24-23.
# 1 8
&
'
'
(
$ 0 1
Short to earth Fault code 17633, cyl. 1
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OCTAVIA Self-Diagnosis 01
Edition 06.00
S00.5126.51.20
------------
------------
Readout on V.A.G 1552
! "
Short to #$ %
&
'
( !
Short to #$ %
&
'
)
0 0
1 2
3
4
0
of fault)
0 0
1 2
5 5
0
6
1 5
1
7
5
3
4
9
#
@
&
B
#
D
&
E % @
F G H F G G
P
$ Q
#
R S R G
T
$
U
&
D E
W
#
X
Y
` G G
a
D
b
X
T
$
U
&
D E
W
#
X
Y
` G G
a
D
b
X
(
! c
d
P #
B D % D
U
&
F G H e
$
U
&
b
d
P #
B D % D
U
&
B
f
% B Q
ShortD % D
U
&
to#
$ %
&
'
g
B D %
#
$ @
#
W
#
h @ @ E B
#
i
#
@
p
E E % @
&
$ %
&
D
'
$ % $ D
&
#
% @
&
D @
p
E E %
W
%
i
B Q D
'
$ % $ D
&
#
% @
&
D @
p
E E %
&
'
% E
& &
#
%
#
@
P
E B @
#
g
% %
#
Q
U
$ %
A W V A
B Q
(
" !
d
P #
B D % D
U
&
(
! "
d
P #
B D % D
U
&
( q
( !
d
P #
B D % D
U
&
T
$
U
&
D E
W
#
X
Y
` S
r
a
D
b
X
T
$
U
&
D E
W
#
X
Y
` S
r
a
D
b
X
T
$
U
&
D E
W
#
X
Y
` S
r
a
D
b
X
9
#
@
&
B
&
$
s
#
@
b
@
&
#
h
e
E %
#
$
s
@
P
$ Q
#
R S R R
9
#
@
& &
'
% E
& &
#
i
$
i
#
D E B
&
% E
U
B
&
P$ Q
#
R S
r
`
9
#
@
&
$ D D
# #
% $
&
E %
P #
W
$
P
E
@
&
E B @
#
B
W
#
%
P
$ Q
#
R S ` R
(
Engine
t
4
u
1
2
v
E B
&
% E h
&
#
w D
# #
W
#
W
x #
$
s
B B
&
$
s
#
@
b
@
&
#
h
9 '
% E
& &
#
i
$
i
#
D E B
&
% E
U
B
&
y G G e
$
U
&
b
or$ D D
# #
% $
&
E %
P #
W
$
P
E @
&
E B @
#
B
W
#
%
Y
$ B
W X
r
e
$
U
&
b
P
E @ @
#
D $
#
e
$
U
&
B Q B
#
%
U
B @ B
#
h
#
% Q
#
B D
b
h E
W
#
&
#
%
#
W A W V A
B Q @
P # #
W
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OCTAVIA01 Self-Diagnosis
Edition 06.00
S00.5126.51.20
------------ 01-20 ------------
Readout on V.A.G 1552
17744
Engine torque monitor
Control limit exceeded
17746
Bank 1, camshaft positionsensor => sender -G1631)
Open/short to positive
17748
Camshaft position/crank-shaft position sensor
Incorrect assignment
Possible cause of fault
Leak in intake system
Throttle valve control unit-J338 faulty or acceleratorpedal position sender-G79 and -G185 faulty;possible cable fault
Signal input in engine con-trol unit faulty (engine con-trol unit faulty)
-G163 faulty Loose contact Open circuit or short cir-
cuit to positive or to earthbetween camshaft posi-tion sensor -G163 and en-gine control unit
Signal from camshaft sen-sor not within tolerance
Possible effects
Engine runs in emergency
mode Altered idling speed
Engine does not rev up tomaximum speed
Poor performance
Start problems
Rectifying fault
- Test intake system for
leaks page 24-22.- Test throttle valve control
unit page 24-56.- Test accelerator pedal po-
sition sender page 24-62.
- Test camshaft positionsensor -G163- page 28-6.
- Rectify open circuit in wir-ing or short circuit accord-ing to CFD
Current Flow Diagrams,Fault Finding and FittingLocations binder
- Test camshaft positionsensor -G163- page 28-6.
- Read measured valueblock, display group 012,display block 3 page 01-37.
1) The camshaft position sensor -G163- is identical with the Hall sender -G40-.
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OCTAVIA Self-Diagnosis 01
Edition 06.00
S00.5126.51.20
------------ 01-21 ------------
Readout on V.A.G 1552
17764
Ignition actuation cyl. 1
Short to positive
17765
Ignition actuation cyl. 1
Short to
17767
Ignition actuation cyl. 2
Short to positive
17768
Ignition actuation cyl. 2
Short to
Possible cause of fault
!
#
$
%
short&
&
topositive
'
!
#
$
%
short &
&
to
'
!
#
$
%
short&
&
to
positive
'
!
#
$
%
short &
&
to
Possible effects
(
&
(
)
%
(
&
(
)
%
(
&
(
)
%
(
&
(
)
%
Rectifying fault
0
est
! 1 2
4
&
#
&
&
or short&
&
& &
5
to $6 7
$
6
7
'
6
6
5
5 6
9
&
%
5
0
est
! 1 2
4
&
#
&
&
or short &
&
& &
5
to $6 7
$
6
7
'
6
6
5
5 6
9
&
%
5
0
est
! 1 2
4
&
#
&
&
or short&
&
& &
5
to$
6 7
$
6
7
'
6
6
5
5 6
9
&
%
5
0
est
! 1 2
4
&
#
&
&
or short &
&
& &
5
to $6 7
$
6
7
'
6
6
5
5 6
9
&
%
5
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OCTAVIA01 Self-Diagnosis
Edition 06.00
S00.5126.51.20
------------ 01-22 ------------
Readout on V.A.G 1552
unit
unit
Engine !
Adaptation limit reached
"
#
$
#
&
Short to positive
' '
"
#
$
#
&
Short to earth
'
"
#
$
#
&
Open circuit
(
)
#
0
of fault
Engine control unit faulty
Engine control unit faulty
Sender rotor faulty
Short circuit to positive be-tween -N80 and enginecontrol unit
-N80 faulty
Short circuit to earth be-tween -N80 and enginecontrol unit
-N80 faulty
Open circuit in wiring be-tween -N80 and fuse
Open circuit in wiring be-tween -N80 and engine
control unit Fuse faulty -N80 faulty
(
)
Engine does not start
Engine does not start
Engine misfires
Smell of fuel in vehicle
Possible jerking in partload range
Possible jerking in partload range
1
2
3
#
0
- Replace engine controlunit page 24-14.
- Replace engine controlunit page 24-14.
- Test engine speed sender-G28 page 28-10.
- Test sender rotor. 1.4-ltr./44 kW Engine, Me-
chanical Components;Repair Group 13; Disas-
sembling and assemblingcylinder block, crankshaftand flywheel
- Test activated charcoal fil-ter solenoid valve -N80 page 01-30, Final con-trol diagnosis.
- Test activated charcoal fil-ter solenoid valve -N80 page 01-30, Final con-trol diagnosis.
- Rectify open circuit in wir-ing or short circuit accord-ing to CFD
Current Flow Diagrams,
Fault Finding and FittingLocations binder- Test fuse.- Test activated charcoal fil-
ter solenoid valve -N80 page 01-30.
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OCTAVIA Self-Diagnosis 01
Edition 06.00
S00.5126.51.20
------------ 01-23 ------------
Readout on V.A.G 1552
-J17
Short to
-J17
Short to
"
#
Idling$
$
%
&
'
value
(
)
1
2
3
4
Idling $
$
%
&
'
value
5
1
2
3
ossile ause of fault
67 8
9
@
A
B
Short2 2
A
to
67 8
9
@
A
B
Short2 2
A
to
"
(
C
D D
C
B
1
E
"
"
2 D
A
D
6
7 F F G @
A
B
or 2 2
3
D
D
3
6
H
9
I
D
3
6
H 8 G
P
@
A
B
R
2
R
@
A
S
D 2 2
A
D
)
D T
E
"
"
2 D
A
D
6
7 F F G @
A
B
or 2 2
3
D
D
3
6
H
9
I
D
3
6
H 8 G
P
@
A
B
R
2
R
@
A
ossile effets
UD T D
3
D
UD T D
3
D
T
A
! 3 0 !
D T
W
3 ! 3 0 !
D T
3
T
A
! 3 0 !
D T
W
3 ! 3 0 !
D T
3
X
Y
%
a
& b
a
%
6 E
@
A
A
1
B
6
7 8
9
T
c d
6
c
9
6 E
@
A
A
1
B
6
7 8
9
T
c d
6
c
9
6 E
! 3 0 !
D T
3
T
c d
6
8
P
6 E
D
C
B
1
@
C
f
A
D 1
3
g
T
c d
6
c c
6 E
2 2
3
6
D
D
3
T
c d
6
h c
6 E
"
"
2 D
A
D
T
c d
6
P
h
6 E
! 3 0 !
D T
3
T
c d
6
8
P
6 E
D
C
B
1
@
C
f
A
D 1
3
g
T
c d
6
c c
6 E
2 2
3
6
D
D
3
T
c d
6
h c
6 E
"
"
2 D
A
D
T
c d
6
P
h
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OCTAVIA01 Self-Diagnosis
Edition 06.00
S00.5126.51.20
------------ 01-24 ------------
Readout on V.A.G 1552
Angle sender for
Implausible signal
Angle sender for
Signal too small
Angle sender for
Signal too large
cause of fault
-G187 faulty or loose con-tact in plug connection forthrottle valve control unit-J338
Signal input in engine con-trol unit faulty (engine con-trol unit faulty)
Incorrect connector as-signment
Open circuit or short cir-cuit to earth in signal ca-ble from -G187 to enginecontrol unit
Open circuit in earth cablefrom -G187 to engine con-
trol unit
effects
Engine runs in emergencymode
Reduced output Irregular idling
Engine runs in emergencymode
Altered idling speed
Engine runs in emergencymode
Cold start problems Cold idling problems
!
"
#
$
%
& '
$
(
)
#
- Test throttle valve controlunit page 24-56.
- Replace engine controlunit page 24-14.
- Test throttle valve controlunit page 24-56.
- Test throttle valve controlunit page 24-56.
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OCTAVIA Self-Diagnosis 01
Edition 06.00
S00.5126.51.20
------------
------------
Readout on V.A.G 1552
Malfunction
! !
"
% & !
Electrical fault in circuit
!
unit' &
Fault in basic setting
(
unit' &
Undervoltage in basic set-ting
ossile
)
0
of fault
Fault in voltage or earthsupply for throttle valvepotentiometer -G69 andthrottle valve positionersender -G127
Open circuit in signal wirefor -G69 and -G127
-G69 and -G127 faulty Throttle valve stiff, or dirty
Open circuit in wiring orshort circuit to positive
Cable has short circuit toearth
-G88 faulty
Adaptation of throttlevalve control unit not per-formed
Voltage below 10 V duringbasic setting
ossile
1 1
0
Increased idling speed Load change jolt when ac-
celerator released
Engine runs in emergencymode
Engine runs in emergencymode
Engine runs in emergencymode
Engine runs in emergencymode
2
1
3
4
1
)
- Test throttle valve controlunit page 24-56.
- Test throttle valve controlunit page 24-56.
- Carry out adaptation ofthrottle valve control unit page 24-56.
- Test throttle valve controlunit -J338 page 24-56.
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OCTAVIA01 Self-Diagnosis
Edition 06.00
S00.5126.51.20
------------
------------
Readout on V.A.G 1552
unit! "
Lower stop is not reached
#
unit! "
Mechanical fault
"
Engine
unit
%
&
'
( (
%
)
(
of fault
Throttle valve jamming Throttle valve positioner
jamming or has mechani-cal damage
Throttle valve jamming Throttle valve positioner
jamming or has mechani-cal damage
Attempt at starting withunauthorised key
Attempt at manipulation Short circuit in communi-
cation line
Incorrect coding Fault in immobiliser sys-
tem Dash panel insert faulty
Engine control unit re-placed and not adapted toimmobiliser
'
( (
%
0 0
(
Start problems Poor throttle response Starting-off problems
Start problems Poor throttle response Starting-off problems
Engine starts and immedi-ately cuts out again
1
0
2
3
0
)
- Inspect throttle valve fordamage or dirt.
- Test throttle valve controlunit page 24-56.
- Inspect throttle valve fordamage or dirt.
- Test throttle valve controlunit page 24-56.
- Adapt engine control unitto electronic immobiliser page 24-39.
- Test electronic immobi-liser:
Electrical System; RepairGroup 96; Servicing elec-tronic immobiliser
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OCTAVIA Self-Diagnosis 01
Edition 06.00
S00.5126.51.20
------------
------------
Readout on V.A.G 1552
unit! " "
Adaptation not started
ossile
#
$
of fault
Incorrect connector as-signment at throttle valvecontrol unit
Throttle valve control unitfaulty
Signal input in enginecontrol unit faulty (controlunit faulty)
ossile
% %
$
Engine runs in emergencymode
Irregular idling
&
%
(
)
%
#
- Inspect connector assign-ment at throttle valve con-trol unit
Current Flow Diagrams,Fault Finding and FittingLocations binder
- Test throttle valve controlunit page 24-56.
- Replace engine controlunit page 24-14.
Notes on fault code 17978:
The electronics for controlling the immobi-liser is located in the dash panel insert andcannot be replaced separately.
If an attempt is made to start the engine witha key which is not adapted, a static fault isstored. If the engine is subsequently startedwith an adapted key, the fault is convertedto a sporadic fault.
Readout on V.A.G 1552
0 0
Voltage$
#
1 1
(
tml." 0
Voltage too small
0
1
2
unit 3
%
0 4 0
2
unit
(
3
3
ossile
#
$
of fault
Battery voltage below10 V
Alternator faulty
Open circuit in wiring
Engine control unit faulty
Incorrect coding
ossile
% %
$
Engine cuts out
Engine does not start
Engine does not start
&
%
(
)
%
#
- Test charge state of bat-tery.
Electrical System; RepairGroup 27; Measuring volt-age under load
- Test alternator.- Rectify open circuit in wir-
ing according to CFD. Current Flow Diagrams,
Fault Finding and FittingLocations binder
- Replace engine controlunit page 24-14.
- Adapt engine control unitto electronic immobiliser page 24-39.
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OCTAVIA01 Self-Diagnosis
Edition 06.00
S00.5126.51.20
------------
------------
Readout on V.A.G 1552
!
!
#
$
%
Signal too small
%
!
!
#
$
%
Signal too large
&
!
!
2#
'
Signal too small
& (
!
!
2#
'
Signal too large
&
$
!
!
) ( #
$
%
0
#
'
Implausible signal
&
1
!
unit
2
3
4
5
6
of fault
Open circuit in wiring orshort circuit to positive
-G79 faulty
Short circuit to positive -G79 faulty
Open circuit in wiring orshort circuit to earth
-G185 faulty
Short circuit to positive -G185 faulty
Open circuit in wiring -G79 and -G185 faulty
Engine control unit faulty
4
5
2 2
Engine runs in emergencymode at fast idling speed
Engine runs in emergencymode at fast idling speed
Engine runs in emergencymode at fast idling speed
Engine runs in emergencymode at fast idling speed
Engine runs in emergencymode at fast idling speed
Engine does not start
7
2
8
! 9
2
6
- Test accelerator pedal po-sition sender page 24-62.
- Test accelerator pedal po-sition sender page 24-62.
- Test accelerator pedal po-sition sender page 24-62.
- Test accelerator pedal po-sition sender page 24-62.
- Test accelerator pedal po-sition sender page 24-62.
- Replace engine controlunit page 24-14.
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OCTAVIA Self-Diagnosis 01
Edition 06.00
S00.5126.51.20
------------
------------
Readout on V.A.G 1552
Faulty
!
No message from ABS
ECU
"
$
$
%
&
$ & '
&
fault ( )
1 2 3
Short to positive
"
$
$
%
&
$ & '
&
fault ( )
1 2 3
Short to earth
4
5
6
( 7 ' $
8
( &
$
9
&
$
of fault
Fault in datalines to ABScontrol unit
Fault in ABS
Fault in datalines to ABS
control unit
Cable has short circuit topositive
Cable has short circuit toearth
Fault stored in faultmemory
9
&
5 5
$
Poor driving characteris-tics (jerky gearshifts, loadchange jolts)
Poor driving characteris-
tics Engine speed varies whenABS activated
Fault lamp does not comeon even if fault exists
Fault lamp comes on andremains onor
Fault lamp also does notcome on when fault exists
Engine operates in emer-gency mode
4
$
5
8
' 7
5
- Test datalines to enginecontrol unit contacts 20,21 and 41 for open circuitand short circuit page24-75.
- Test ABS control unit. Running Gear; Repair
Group 45
- Test databus line page
24-75.
- Test dash panel insert. Electrical System; Repair
Group 90; Dash Panel In-sert
- Test dash panel insert. Electrical System; Repair
Group 90; Dash Panel In-sert
- Interrogate and erase faultmemory page 01-4.
- Rectify cause of fault andconduct road test.
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OCTAVIA01 Self-Diagnosis
Edition 07.99S00.5126.50.20
------------ 01-30 ------------
Final control diagnosis
With final control diagnosis the following com-ponents are actuated in the order stated:
1. Fuel pump relay (J17)
2. Solenoid valve 1 for activated charcoal filter(N80)
Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3
Test condition
l Fuses o.k.
Note:To repeat final control diagnosis without havingswitched on the engine in-between, switch offignition for about 20 seconds.
Procedure
- Connect vehicle system tester V.A.G 1552 andselect engine electronics (address word 01);ignition is switched on for this step page01-2.
KReadout in display:
- Press keys 0 and 3 for the function Finalcontrol diagnosis.
KReadout in display:
- Confirm the entry with the key Q.
Operate fuel pump relay (J17).
KReadout in display:
The fuel pump relay (on relay plate, relay po-sition 4) must continue clicking until the nextcontrol element is actuated by pressing the key.
Note:
During actuation of the fuel pump relay, it mustalso be possible to hear the fuel pump operat-ing at intervals.
Test of vehicle systems HELPSelect function XX
Test of vehicle systems Q03 - Final control diagnosis
Final control diagnosis Fuel pump relay -J17
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OCTAVIA Self-Diagnosis 01
Edition 07.99S00.5126.50.20
------------ 01-31 ------------
If the relay does not click:
- Test the fuel pump relay page 24-27.
- Press the
key.
Actuate solenoid valve 1 for activated charcoalfilter (N80).
- Press the
key.
KReadout in display:
The solenoid valve (in front of coolant reser-voir on right) must click until the next controlelement is actuated by pressing the
key.
If the solenoid valve does not click:
- Test solenoid valve 1 for activated charcoalfilter page 24-49.
KReadout in display:
- Press the
key.
KReadout in display:
- Press keys 0 and 6 for the function End out-put and confirm the entry with the key Q.
- Switch off the ignition.
Note:
After ending final control diagnosis, it is neces-sary to switch off the ignition. If the ignition isnot switched off before again starting the en-gine, the engine is not able to start as the injec-tors and the ignition transformer are not actu-ated.
Final control diagnosis Solenoid valve 1 for activated charcoal filter -N80
Final control diagnosis
END
Test of vehicle systems HELPSelect function XX
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OCTAVIA01 Self-Diagnosis
Edition 07.99S00.5126.50.20
------------ 01-32 ------------
Reading measured value block
Test conditions
l Coolant temperature at least 80 C
l Electrical components switched off (radiatorfan must not cut in during the test)
Test sequence:
- Connect vehicle system tester V.A.G 1552and select engine electronics (address word01); engine idling for this step page 01-2.
KReadout in display:
- Press keys 0 and 8 for the function Readmeasured value block and confirm the en-
try with the key Q.
KReadout in display:
- Enter the desired three-digit display groupnumber and confirm the entry with the key Q.
KReadout in display:
KReadout in display (example) for display group001:
Note:
Proceed as follows to switch to another displaygroup:
Test of vehicle systems HELPSelect function XX
Read measured value blockDisplay group number XXX
Read measured value block 0
1 2 3 4 5 6 7 8 9 10
Read measured value block 1
1 2 3 4
Display group V.A.G 1552 V.A.G 1551
higher Press key Press key 3
lower Press key Press key 1
skipping Press key C Press key C
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OCTAVIA Self-Diagnosis 01
Edition 07.99S00.5126.50.20
------------ 01-33 ------------
Display group 000 (decimal readouts)
Engine idling (coolant temperature not below 80 C) All electrical components switched off
1 2 3 4 5 6 7 8 9 10 K Display blocks Specification Equals
Learned value of mixture formation part load 110...145 7...+7 %
Learned value of mixture formation idling 125...131 2.25...+3 ms
Control value of mixture formation 100...155 11...+11 %
Learned value of idling speed stabilisation 101...154 10...+10 %
Idling speed controller 100...155 11...11 %
Throttle valve angle 4...12 2...6
Vehicle electrical system voltage 110...150 11...15 V
Engine speed (idling speed) 23...27 730...870 rpm
Ignore readout 255
Coolant temperature 164...201 75...103 C
Reading measured value block: display groups 000 to 010
Analysis of display group 000
Readout in V.A.G 1552
less than 164
greater than 201
Possible cause of fault
Engine too cold
Coolant temperature sender or cable connection toengine control unit
Radiator dirty
Radiator fan not operating
Coolant thermostat faulty
Coolant temperature sender or cable connection toengine control unit
Rectifying fault
- Conduct road test, if necessary.- Test coolant temperature sender
-G62- page 24-34.
- Clean radiator.- Test operation of radiator fan.- Test coolant thermostat.- Test coolant temperature sender
-G62- page 24-34.
Display block: 1 Coolant temperature
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OCTAVIA01 Self-Diagnosis
Edition 07.99
S00.5126.50.20
------------ 01-34 ------------
Display block: 3 Engine speed (idling speed)
Readout in V.A.G 1552
less than 23
greater than 27
Possible cause of fault
Throttle valve control unit -J338 jamming or faulty
Throttle valve control unit -J338 jamming or faulty Large quantity of unmetered air (cannot be compen-
sated for (balanced) by idling speed stabilisation)
Rectifying fault
- Test throttle valve control unit page24-56.
- Test throttle valve control unit page24-56.
- Rectify unmetered air.
Display block: 4 Vehicle electrical system voltage
Readout in V.A.G 1552
less than 110
greater than 150
Possible cause of fault
Alternator faulty, battery severely discharged Battery severely discharged shortly after start by
high charge current and by ancillaries Contact resistance in power supply or in earth con-
nection for engine control unit Power drain when ignition off
Voltage regulator at alternator faulty
Overvoltage caused by jump-starting aid or quick-charger
Rectifying fault
- Test voltage, charge battery.- Increase revs slightly for a few min-
utes and switch off ancillaries.- Test voltage supply of engine control
unit page 24-38.- Eliminate power drain.
- Test voltage, replace regulator, if nec-
essary.- Interrogate fault memory page 01-4.
Display block: 5 Throttle valve angle
Readout in V.A.G 1552
less than 4
greater than 12
Possible cause of fault
Throttle valve potentiometer in throttle valve controlunit -J338 faulty or incorrectly set
Unmetered air between intake manifold and airmass meter (causes fast idling speed; the throttlevalve control unit attempts to control fast idlingspeed to specified idling speed
Adaptation of throttle valve control unit -J338 notperformed
Throttle valve potentiometer in throttle valve controlunit -J338 faulty or incorrectly set
Throttle valve jamming
Rectifying fault
- Test throttle valve control unit -J338 page 24-56.
- Rectify causes of unmetered air.
- Perform adaptation of throttle valvecontrol unit -J338 page 24-56.
- Test throttle valve control unit -J338 page 24-56.
Display block: 6 Idling speed controller
Readout in V.A.G 1552
less than 100greater than 155
Possible cause of fault
Throttle valve potentiometer in throttle valve controlunit -J338 faulty or incorrectly set
Rectifying fault
- Test throttle valve control unit -J338 page 24-56.
- Perform adaptation of throttle valve