Manual Skoda Octavia 1,4 33kw 3PB

8/3/2019 Manual Skoda Octavia 1,4 33kw 3PB

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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

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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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Service OCTAVIA

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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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Service

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OCTAVIA Self-Diagnosis 01

Edition 07.99

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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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.


- For the further procedureRepair Descrip-tions.


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Test of vehicle systems HELP

Select function XX

Interrogating and erasing fault

memory


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.


- 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.


- 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.


X faults recognized!


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- 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.


- 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!



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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.


- 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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16501


Signal too small

16502


Signal too large

16514

Bank 1, probe 1

Electrical fault in circuit

16515

Bank 1, probe 1

Voltage too small


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









Lambda closed-loop con-trol switches to open-loop

Poor idling Increased emission levels



Poor idling

Emission levels not o.k.


Rectifying fault





- 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


- Read measured valueblock, display group 030 page 01-38.



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16516

Bank 1, probe 1

Voltage too large

16517

Bank 1, probe 1

Signal too slow

16518

Bank 1, probe 1

No activity


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


Poor idling Emission levels not o.k. Increased fuel consump-

tion



Carbon deposits on sparkplugs

Rectifying fault

- Rectify short circuit or

open circuit in wiring Current Flow Diagrams,

Fault Finding and FittingLocations binder




- 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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16554

Bank 1, fuel metering sys-tem

Malfunction

16555


System too lean


Fuel pressure regulatorfaulty

Injectors faulty

Fuel system faulty

Lambda probe faulty

Possible effects

Engine does not start Increased emission levels Poor starting characteris-

tics


Poor idling



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.






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16556


System too rich

16705

Engine speed sender -G28

Implausible signal

16706


No signal

16711

Knock sensor 1 -G61

Signal too small

16712

Knock sensor 1 -G61

Signal too large


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


Poor idling

Engine misfires

Engine does not start

Engine cuts out

High fuel consumption

Reduced power

High fuel consumption Reduced power

Rectifying fault





- Test engine speed sender-G28 page 28-10.

- Rectify open circuit in wir-ing or short circuit.


- 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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16719


Malfunction

16725

Camshaft position sensor=> sender -G40

Implausible signal

16726

Camshaft position sensor=> sender -G40

Signal too small


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-


Voltage supply or earthsupply for camshaft posi-tion sensor -G1631) faulty

-G163 faulty Signal input in engine con-


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 cuts out

Engine does not rev up tomaximum speed

Poor performance

Start problems

Valve timing loud, reducedengine output


Poor performance

Start problems

Rectifying fault

- Rectify open circuit in wir-

ing or short circuit. Current Flow Diagrams,




- Test camshaft position sen-sor -G163 page 28-6

- Rectify open circuit in wir-ing or short circuit accord-ing to current flow diagram


- 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


1) The camshaft position sensor -G163 is identical with the Hall sender -G40.


20/138


Edition 06.00

S00.5126.51.20

------------ 01-12 ------------


16825

Tank vent system

Flow faulty

16885

Vehicle speed signal

Implausible signal


-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



- Rectify open circuit in wir-ing or short circuit.


- Test vehicle speed signal page 24-65.


21/138


Edition 06.00

S00.5126.51.20

------------ 01-13 ------------


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


1

&

0 0

Poor driving characteris-

tics


Smell of fuel

Brake light does not comeon

Variations in engine speedduring brake application

Poor driving characteris-tics

Variations in engine speedwhen ABS activated



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


- Test databus page 24-75.

- Replace engine control

unit page 24-14.



22/138


Edition 06.00

S00.5126.51.20

------------

------------


unit

!

"

#

$

&

'

eating

)

Short to positive

!

1

"

#

$

&

'

eating

)

Insufficient capacity

ossible #

)

0

of fault


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


Irregular idling Emission levels not o.k.

Irregular idling


1

2

3

#

)



- Rectify short circuit ac-cording to CFD



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,



- Replace lambda probe.

- Test fuel pump relay and

actuation

page 24-27.


23/138


Edition 06.00

S00.5126.51.20

------------

------------


" #

#

%

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



Reduced output

4

#

3

5

"

3

%



- Replace lambda probe. 1.4-ltr./44 kW Engine, Me-

chanical Components;Repair Group 26; Remov-ing and installing parts ofexhaust system


- Rectify open circuit in wir-ing.



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.


24/138


Edition 06.00

S00.5126.51.20

------------

------------


! " # #

$

"

#

"

&

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

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E

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7

in T6 1 U

B

8

C

0

4

8 3

short E6

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G

7

to0 8 6

7

4

HI

P

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7

S

Short E6

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7

to0 8 6

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4

in E8

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C

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Possible

A

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f

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response

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response

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est1

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C

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p

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G

)

w w u

p

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C

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w Q

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v

H

t

est1

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V

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5

X

7

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) 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

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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

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0 ) 8

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0 0 1 U 1 0

E

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7

6 5

G

1

7

) 8 U 0

Y u

H

Q u


25/138


Edition 06.00

S00.5126.51.20

------------

------------


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


-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


Altered idling speed

2

1

3

4


- Test intake manifold tem-perature sender -G72 page 24-31.






26/138


Edition 06.00

S00.5126.51.20

------------

------------


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


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 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



# 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


27/138


Edition 06.00

S00.5126.51.20

------------

------------


! "

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

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T

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a

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a

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b

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(

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d

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B D % D

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$

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X

Y

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r

a

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b

X

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U

&

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W

#

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Y

` S

r

a

D

b

X

T

$

U

&

D E

W

#

X

Y

` S

r

a

D

b

X

9

#

@

&

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&

$

s

#

@

b

@

&

#

h

e

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#

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s

@

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'

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i

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#

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&

% E

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&

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#

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r

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9

#

@

&

$ D D

# #

% $

&

E %

P #

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P

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@

&

E B @

#

B

W

#

%

P

$ Q

#

R S ` R

(

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t

4

u

1

2

v

E B

&

% E h

&

#

w D

# #

W

#

W

x #

$

s

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&

$

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


28/138


Edition 06.00

S00.5126.51.20

------------ 01-20 ------------


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


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


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.



- Test camshaft positionsensor -G163- page 28-6.


1) The camshaft position sensor -G163- is identical with the Hall sender -G40-.


29/138


Edition 06.00

S00.5126.51.20

------------ 01-21 ------------


17764

Ignition actuation cyl. 1

Short to positive

17765


Short to

17767


Short to positive

17768


Short to


!

#

$

%

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


30/138


Edition 06.00

S00.5126.51.20

------------ 01-22 ------------


unit

unit

Engine !

Adaptation limit reached

"

#

$

#

&

Short to positive

' '

"

#

$

#

&

Short to earth

'

"

#

$

#

&

Open circuit

(

)

#

0

of fault



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 misfires

Smell of fuel in vehicle

Possible jerking in partload range

Possible jerking in partload range

1

2

3

#

0




- 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.


Current Flow Diagrams,

Fault Finding and FittingLocations binder- Test fuse.- Test activated charcoal fil-

ter solenoid valve -N80 page 01-30.


31/138


Edition 06.00

S00.5126.51.20

------------ 01-23 ------------


-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


32/138


Edition 06.00

S00.5126.51.20

------------ 01-24 ------------


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


Reduced output Irregular idling


Altered idling speed


Cold start problems Cold idling problems

!

"

#

$

%

& '

$

(

)

#






33/138


Edition 06.00

S00.5126.51.20

------------

------------


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





2

1

3

4

1

)



- Carry out adaptation ofthrottle valve control unit page 24-56.

- Test throttle valve controlunit -J338 page 24-56.


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Edition 06.00

S00.5126.51.20

------------

------------


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.


- Inspect throttle valve fordamage or dirt.


- Adapt engine control unitto electronic immobiliser page 24-39.

- Test electronic immobi-liser:

Electrical System; RepairGroup 96; Servicing elec-tronic immobiliser


35/138


Edition 06.00

S00.5126.51.20

------------

------------


unit! " "

Adaptation not started

ossile

#

$

of fault

Incorrect connector as-signment at throttle valvecontrol unit

Throttle valve control unitfaulty


ossile

% %

$


Irregular idling

&

%

(

)

%

#

- Inspect connector assign-ment at throttle valve con-trol unit




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.


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


Incorrect coding

ossile

% %

$

Engine cuts out



&

%

(

)

%

#

- 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,



- Adapt engine control unitto electronic immobiliser page 24-39.


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Edition 06.00

S00.5126.51.20

------------

------------


!

!

#

$

%

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


4

5

2 2

Engine runs in emergencymode at fast idling speed






7

2

8

! 9

2

6

- Test accelerator pedal po-sition sender page 24-62.







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Edition 06.00

S00.5126.51.20

------------

------------


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.


38/138


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)


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.


- Press keys 0 and 3 for the function Finalcontrol diagnosis.


- Confirm the entry with the key Q.

Operate fuel pump relay (J17).


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 Q03 - Final control diagnosis

Final control diagnosis Fuel pump relay -J17


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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.


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.


- Press the

key.


- 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



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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.


- Press keys 0 and 8 for the function Readmeasured value block and confirm the en-

try with the key Q.


- Enter the desired three-digit display groupnumber and confirm the entry with the key Q.


KReadout in display (example) for display group001:

Note:

Proceed as follows to switch to another displaygroup:


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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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


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


42/138


Edition 07.99

S00.5126.50.20

------------ 01-34 ------------

Display block: 3 Engine speed (idling speed)


less than 23

greater than 27


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


less than 110

greater than 150


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


less than 4

greater than 12


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 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.


Display block: 6 Idling speed controller


less than 100greater than 155



Rectifying fault


- Perform adaptation of throttle valve

Manual Skoda Octavia 1,4 33kw 3PB

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