Manual Service Workshop Manual Octavia Engine Fuel Injection 1.9tdi 01-23-28

Service
Workshop Manual
OCTAVIA
1.9-ltr. / 66 kW (TDI) Engine
Fuel Injection and Glow Plug System
Service Department. Technical Information

S00.5111.50.20
Edition 08.96
The Workshop Manual is intended only for use within the KODA
Organisation; it is not permitted to pass it on to third parties.
1996 KODA, automobilov a.s.
Printed in Czech Republic
Service
List of Supplements to
Workshop Manual OCTAVIA
Edition: 01.04
1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Replaces List of Supplements - Edition: 09.03
Supplement
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Edition
08.96
05.97
03.98
02.99
12.00
09.03
01.04
Subject
Article Number
Basic Edition of Workshop Manual
S00.5111.50.20
Supplement to Basic Edition

Modifications for Vehicles 08.97
Modification of Fault Code
Modifications for Vehicles 08.00
Supplement to Repair Group 01 and 23
Supplement to Repair Group 01 and 23
S00.5111.51.20
S00.5111.52.20
S00.5111.53.20
S00.5111.54.20
S00.5111.55.20
S00.5111.56.20
Contents next page.
The Service Manual is intended only for use within the

koda Organisation; it is not permitted to pass it on to
third persons.
2004 KODA AUTO a. s.
Printed in CR
S00.5111.56.20
OCTAVIA
01
Contents
Service
Self-Diagnosis
Self-Diagnosis ..............................................................................................................................
- Properties of the self-diagnosis ................................................................................................
- Technical data of self-diagnosis ...............................................................................................
- Connecting tester V.A.G 1552 and select engine electronics control unit ................................
- Interrogating and erasing fault memory ....................................................................................
- Fault table .................................................................................................................................
Page
01-1
01-1
01-1
01-2
01-5
01-8
Actuator diagnosis ......................................................................................................................

- Performing actuator diagnosis .................................................................................................
- Basic setting .............................................................................................................................
- Coding control unit ...................................................................................................................
01-18
01-18
01-21
01-23
Measured value blocks ...............................................................................................................

- Reading measured value block ................................................................................................
- Display nominal values for general vehicle inspection .............................................................
- Display nominal values for injection pump ...............................................................................
- Display nominal values for engine idling ..................................................................................
- Display nominal values for exhaust gas recirculation ..............................................................
- Display nominal values for temperature sensor .......................................................................
- Display nominal values for automotive power ..........................................................................
- Display nominal values for charge pressure control ................................................................
01-28.2
01-28.2
01-29
01-38
01-46
01-49
01-51
01-52
01-58
Readiness code ...........................................................................................................................

- Reading readiness code ...........................................................................................................
- Generate readiness code .........................................................................................................
23
Fuel Formation/Injection
Servicing a diesel direct fuel injection system .........................................................................

- Safety measures ......................................................................................................................
- Rules for cleanliness ................................................................................................................
- Overview of fitting locations 07.97 .......................................................................................
- Overview of fitting locations 08.97 07.00 .............................................................................
- Overview of fitting locations 08.00 .......................................................................................
- Assembly overview of injection pump ......................................................................................
- Assembly overview of fuel filter ................................................................................................
- Assembly overview of throttle mechanism ...............................................................................
- Adjusting sender for accelerator pedal position .......................................................................
- Disassembling and assembling air filter ...................................................................................
- Removing and installing injection pump ...................................................................................
- Dynamically testing and setting commencement of injection ...................................................
- Removing and installing and testing injection nozzles .............................................................
- Wiring and Component Test with Test Box ..............................................................................
- Replacing engine control unit ...................................................................................................
Inspecting the charge air pressure system ..............................................................................
- Inspecting charge air pressure .................................................................................................
- Inspecting charge pressure control solenoid valve (N75) ........................................................
- Inspecting intake manifold temperature sender (G72) .............................................................
- Inspecting intake manifold pressure sender (G71) and altitude sender ...................................
- Hose layout plan for charge pressure control ...........................................................................
Testing injection control .............................................................................................................

- Testing injection timing device control range ............................................................................
- Testing the commencement of injection valve (N108) .............................................................
- Inspecting fuel temperature sender ..........................................................................................
Edition 01.04
S00.5111.56.20
01-24
01-24
01-26
Page
23-1
23-1
23-1
23-2
23-2.2
23-3.1
23-4
23-5
23-6
23-7
23-7.2
23-8
23-13
23-16
23-19
23-20
23-22
23-22
23-24
23-25
23-26
23-27
23-28
23-28
23-29
23-30
------------ I ------------
Service
OCTAVIA
Inspecting exhaust gas recirculation system ...........................................................................

- Inspecting exhaust gas recirculation ........................................................................................
- Inspecting exhaust gas recirculation valve (N18) .....................................................................
- Inspecting air mass meter (G70) ..............................................................................................
- Vacuum plan of hose layout plan for the exhaust gas recirculation system .............................
23-32
23-32
23-34
23-35
23-37
Inspecting control units input quantities ..................................................................................

- Testing voltage supply for diesel direct injection system ..........................................................
- Testing engine speed sender (G28) .........................................................................................
- Testing needle lift sender (G80) ...............................................................................................
- Testing coolant temperature sender (G62) ...............................................................................
- Testing brake light switch and brake pedal switch ...................................................................
- Testing modulating piston movement sender (G149) and metering adjuster (N146) .............
- Testing accelerator pedal position sender (G79) ......................................................................
23-38
23-38
23-41
23-42
23-43
23-44
23-45
23-47
Servicing intake manifold 08.97 ............................................................................................

- Inspecting the change-over of the intake manifold flap ............................................................
- Hose layout plan for intake manifold flap operation .................................................................
23-56
23-57
23-59
Testing auxiliary signals .............................................................................................................

- Testing signals from/to the air conditioning system ..................................................................
- Testing clutch pedal switch (F36) .............................................................................................
- Testing speed signal .................................................................................................................
- Testing engine speed signal .....................................................................................................
- Activating or deactivating cruise control system .......................................................................
- Testing cruise control system ...................................................................................................
- Testing CAN-Bus databus ........................................................................................................
28
Glow plug system
Inspecting glow plug system .....................................................................................................

- Inspecting proper operation ......................................................................................................
- Inspecting glow plugs ...............................................................................................................
- Inspecting glow period warning lamp .......................................................................................
------------ II ------------
23-49
23-49
23-51
23-52
23-53
23-54
23-55
23-55.3
Page
28-1
28-1
28-2
28-2
Edition 01.04
S00.5111.56.20
OCTAVIA
01
Self-diagnosis
Self-diagnosis
Features of self-diagnosis
The diesel direct injection system control unit is
equipped with a fault memory. The fault memory
is designed as a permanent memory and as a
volatile memory.
If faults occur in the monitored sensors or components, these are stored in the fault memory
together with an indication of the fault type.
The engine control unit analyses this fault information and distinguishes the fault types page
01-8, Fault Table, and stores these faults until
the contents of the fault memory are erased.
Faults which occur only temporarily (sporadically), are displayed as sporadic by the addition /SP. The cause of a sporadic fault may
be, for example, a loose contact or a temporary
open circuit in the wiring. If a sporadic fault no
longer occurs within 50 engine starts, it is automatically erased from the fault memory.
The stored faults can be read out with the vehicle system tester V.A.G 1552 or V.A.G 1551, or
also with VAS 5051 page 01-5.
After any faults have been rectified, it is then
necessary to erase the fault memory page
01-6.
Notes:
The description which follows relates only to
the vehicle system tester V.A.G 1552 using
the programme card version 5.0.
If see info in literature appears in the display of the vehicle system tester, look for the
appropriate text in the fault table on the basis of the fault code.
Use of the fault reader V.A.G 1551 (with programme card version 8.0) with integrated
printer, or VAS 5051, is similar. Slight variations are possible in the readouts in the display.
Technical data of self-diagnosis

Interrogating control unit version
The control unit version is displayed when the
vehicle system tester V.A.G 1552 is connected
and the engine electronics control unit is selected page 01-2.
Edition 12.00
S00.5111.54.20
------------ 01-5 -----------01-1
01
OCTAVIA
Self-diagnosis
Functions available when using vehicle system tester V.A.G 1552

Please refer to the table below for the requirements necessary to enable you to select the
desired functions.
Function
Condition
Engine not
running,
ignition on
Engine
idling
yes
yes
yes1)
yes
01 Interrogate control unit

version
02 Interrogate fault memory

03 Final control diagnosis
yes
yes
05 Erase fault memory
yes
yes
07 Code control unit
yes
no
04 Basic setting
06 End output
08 Read measured value

block
1)
no
yes
yes
yes
yes
yes
Only perform when ignition switched on if

engine does not start (operate starter first
of all for at least 6 seconds).
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, 3A, 3B or 3C
Test conditions
l Battery voltage at least 11.5 V
l Fuse 12 o.k.
l Earth connections at gearbox and on left

below battery o.k.
------------ 01-2 ------------
Edition 12.00
S00.5111.54.20

OCTAVIA
01
Self-diagnosis
K-
Connect vehicle system tester V.A.G 1552

with cable V.A.G 1551/3, 3A, 3B or 3C.
After the vehicle system tester has been connected:

-
Depending on the desired function, switch

the ignition on or start the engine page
01-2, table of Available functions.
If the readouts which appear in the display do

not correspond to the description in the procedure, refer to the following notes:
Notes:
Test of vehicle systems

Control unit does not answer
HELP

Error in establishing communication
HELP

K wire not switching to earth
HELP

K wire not switching to positive
HELP

Enter address word XX
HELP
Edition 12.00
S00.5111.54.20
If Error in data transmission is displayed

because of an input error, disconnect cable
at vehicle system tester, plug it in again and
repeat the steps.
K If one of the following messages appears in

the display, perform fault finding according
to diagnostic cable fault finding programme:
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder, or
Operating Instructions of vehicle system
tester
Note:
Operate the vehicle system tester on the basis

of the readout in the display.
K Readout in display:
-
Enter address word 01 for Engine electronics and confirm the entry with the key Q.
------------
------------
01
OCTAVIA
Self-Diagnosis
038906018BQ 1.9 l R4 EDC G00SG 2112

Coding 00002
WSC 01234
K The control unit identification appears in the display, e.g.:

038906018BQ Part no. of control unit part1)
1.9 l
R4
EDC
Engine displacement
Engine displacement version (4 cyl. in-line engine)

Injection system (Electronic
Diesel Control)
G or no
display
Vehicle with or without

cruise control system
MG
AG
Manual gearbox
Automatic gearbox
00
2112
Control unit mapping
Data status (software version) of control unit
Coding 00002 Coding variant of control unit

WSC 01234
Workshop code from the

vehicle system tester V.A.G
1552 with which the last
coding was performed
List of all control units

Part no. of CU1)
Software
version
Starting date
038906018B
1002
08.97
038906018BC
1822
038906018GM
2162
038906018BQ
08.98
2112
08.98 04.99
038906012F
3313
08.00
038906012HA
4922
038906012H
1)
3315
05.99 07.00
08.00
08.03
For current control unit version - spare parts

catalogue
Notes:
If the control unit version displayed does not
correspond to the vehicle, replace the control
unit page 23-20.
Incorrect coding of the engine control unit results in:
poor driveability (jerking when changing
gears, load alteration shock etc.)
Increase in fuel consumption
Increase in pollution
------------ 01-4 -------------
Edition 09.03
S00.5111.55.20
OCTAVIA
01
Self-diagnosis
Storage of non-existent faults in fault memory
Functions not being performed
Reduction in life of automatic gearbox

If the code does not match the corresponding
version in the vehicle:
Select function XX
HELP
Check coding of engine control unit page

01-23, Coding engine control unit.
Press key.
-
For further procedure Repair descriptions.
Interrogating and erasing fault

memory
V.A.G 1551/3, 3A, 3B or 3C
Interrogating fault memory
-

with cable and select engine electronics control unit (address word 01). Engine should
be idling for this step.
(Connecting vehicle system tester and selecting engine electronics control unit page
01-2).
Only if the engine does not start:

Select function XX
HELP
Switch ignition on.
-
Enter 02 for the function Interrogate fault

memory and confirm the entry with the key
Q.
K The number of stored faults or No fault recognized! appears in the display.
X faults recognized!
If no fault is stored:
Select function XX
Edition 12.00
S00.5111.54.20
HELP
Press key.
-
Enter 06 for the function End output and

confirm entry with the key Q.
------------ 01-9 -----------01-5
01
Self-Diagnosis
OCTAV1A
If one or several faults are stored:

Fault number: 00542
Needle lift sender -G80
Short-circuit to earth
K Read-out of fault number on display, e.g.:

-
Press key.
Press key.
K Fault source and fault type appear in the display, e.g.:

-
Press key.
The stored faults are displayed in sequence.

Vehicle system test
Select function XX
HELP
Press key.
K Read-out on display:
-
Enter 06 for the function end output and

confim entry with key Q.
Rectify fault by referring to the fault table

page 01-8.
Note:
When carrying out test and removal and installation operations, faults, such as connectors
unplugged, may also be detected by other control units. This is why, when the work is concluded, that it is necessary to interrogate and
erase the fault memory on all control units. For
this you must proceed as follows:
-
Enter 00 twice for the address word Automatic check sequence and confirm entry
with Q key. The -V.A.G 1552- sends all known
address words in sequence.
Erasing fault memory

Test condition
l Rectifying fault
Note:
After fault elimination the fault memory must

again as described be interrogated and subsequently erased.
For vehicles 08.03
Whenever the fault memory is erased, it is necessary to generate a readiness code page
01-26.
-
------------ 01-6 -------------
Connect vehicle system tester -V.A.G 1552and select the engine electronics control unit
(address word 01). The engine must be running in idle.
(Connect vehicle system and select engine
electronics control unit page 01-2).
Edition 01.04
S00.5111.56.20
OCTAVIA

Select function XX
01
Self-Diagnosis
HELP
-
X faults recognized
Press the keys 0 and 2 for the function Interrogate fault memory and confirm the entry with the key Q.
K The number of stored faults appears in the display.

If one or several faults are stored:
The stored faults are displayed one after the
other.

Select function XX
HELP
K After the stored faults have been displayed, the

following readout appears:
-

Fault memory is erased
Press the keys 0 and 5 for the function Erase

fault memory and confirm the entry with the
key Q.
Note:
If you have switched off the ignition between
Interrogating fault memory and Erasing fault
memory, the fault memory is not erased.
-
Press the keys 0 and 6 for the function End

output and confirm the entry with the key Q.
Edition 02.99
S00.5111.53.20
Press the key.
Carry out a road test. During the road test,

once again interrogate the fault memory. No
further faults should be displayed.
------------ 01-7 ------------
01
Self-Diagnosis
Fault table
Notes:
For vehicles 08.98 , different fault codes
with the same or similar texts are displayed.
The required text is to be selected in the fault
table according to the fault code.
If the display of the vehicle system tester
reads Information in the literature the required text is to be found in the fault table
according to the fault code.
The fault table is ordered according to the
fault code on the left.
Explanations concerning the types of faults

(e.g. Interruption or short-circuit to earth):
Readout on V.A.G 1552
old
Fault number
00513
new
Possible cause of fault
16705
Engine speed
sender -G28
Implausible signal
No signal
00519
16706
17563
Line interruption/short-circuit
to earth
Supply voltage
17564
17565
17566
------------ 01-8 -------------
If components are output as faulty:

First check all cables and connectors to these
components as well as the earth connections
according to the Current Flow Diagram. Replace the component only if this test does
not reveal any fault. This applies in particular for faults that are output as sporadically
occurred (SP) faults.
Possible effects
Poor starting
Irregular engine running,
misfiring
Increased idling speed
Glow period indicator light
flashes
Reduced performance
No display on rev counter
Engine does not start
Short-circuit to positive
-G71 defective
Poor performance
Intake manifold
sender -G71
Short-circuit to
positive
Operating instructions for vehicle system

tester
Bent or loose sensor

washer
Distance to speed sender/
sensor rotor too great
Metallic swarf on engine
speed sender -G28
Line interruption of
screening
-G28 defective
-G28 defective
Line interruption or shortcircuit
Line interruption of
screening.
Line interruption or shortcircuit to earth

-G71 defective
OCTAVIA
Rectifying fault
- Remove noise insulation

and check sensor washer
- Check engine speed sensor
page 23-41
- Check intake manifold

pressure
page 23-26
- Check sender -G71

- Check intake system for
leaks
page 23-27
Edition 09.03
S00.5111.55.20
OCTAVIA
01
Self-Diagnosis

Fault number
old
Rectifying fault
Black exhaust when starting

Engine preheater does not
operate
Preglowing always operates for about 20 seconds
- Test coolant temperature

sender page 23-43
Engine preheater does not

operate
- Test intake manifold temperature sender

page 23-25
new
00522
Possible effects
17663
Coolant temperature
sender -G62
-G62 faulty
Cable has short circuit to
earth
Short circuit to
earth
Open/short
circuit to positive
00527
17664
-G62 faulty
Open circuit in wiring or
cable has short circuit to
positive
17568
Intake manifold temperature sender -G72

Short circuit to
earth
Open/short
circuit to positive
00532
-G72 faulty
earth
17569
-G72 faulty
short circuit to positive
18008
Supply voltage
Control unit was connected when ignition on
as appropriate

short circuit
Voltage supply tml.

15
Voltage too low
Voltage not present when

ignition on (terminal 15)
Diesel direct injection system control unit -J248

faulty
Voltage supply relay terminal 30 (J322) faulty
Edition 02.99
S00.5111.53.20
- Erase fault memory and

continue checking vehicle
Engine stops
- Test voltage supply of diesel direct injection system

control unit page 23-38
- Test voltage supply of terminal 15
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
- Replace control unit
page 23-20
- Test voltage supply of diesel direct injection system
control unit page 23-38
------------
Implausible signal
------------
01
OCTAVIA
Self-Diagnosis

Fault number
old
Rectifying fault
new
00539
Possible effects
17570
Fuel temperature
sender -G81
-G81 faulty
earth
Several faults stored

Engine stops
- Check plug connection for

injection pump
-G80 faulty
short circuit
Glow indicator lamp

flashes
Rough engine running
Reduced output
- Test needle lift sender

page 23-42
Fuel supply (was) interrupted: tank has run

empty, feed line or filter
blocked, system drawing
in air
Fault 00550 Commencement of injection control

possible
Misfiring, jerking
- Check fuel system
Engine stops
Misfiring
- Check cable connection

and plug connection at injection pump
Sender plate of engine

speed sender bent or
loose
Misfiring at exactly
3000 rpm
- Take off oil pan and inspect sender plate
-G80 faulty
Misfiring, jerking (particularly at high revs)
- Replace needle lift sender
Injection pump faulty
00542
17571
- Test fuel temperature

sender page 23-30
(Sporadic) open circuit in

wiring to fuel cut-off valve
Open/short
circuit to positive
Reduced output
Connector for injection

pump separated
Short circuit to
earth
Fault 01268 quantity adjuster control difference

stored
misfiring
No throttle response after
overrun
- Replace injection pump
-G80 faulty
Sporadic open circuit in
wiring (cable break)
Glow indicator lamp

flashes
Misfiring, jerking
Reduced output

page 23-42
-G81 faulty
17653
Needle lift sender

-G80
Short circuit to
earth
Implausible signal
Open/short
circuit to positive
------------ 01-10 ------------
17654
17655
Edition 02.99
S00.5111.53.20
OCTAVIA
01
Self-Diagnosis

Fault number
old
00545
Possible effects
Rectifying fault
new
-
Engine/gearbox electrical connection 1)

short circuit
- Test signals from/to automatic gearbox

A - Signal for gearshift
Commencement of delivery not o.k.
Poor performance at
higher revs
Engine difficult to start
- Test and set commencement of injection

page 23-13
Adjustment travel of injection pump blocked (dirt,

swarf)
00550
Hard gearshifts
Poor performance at
higher revs
- Test injection timing control range page 23-28
17656
Commencement of
injection control
Control difference
Engine was stalled (within

the last 50 starts)
- Erase fault memory, continue checking vehicle
Fuel feed (was) interrupted: tank has run

empty, feed line or filter
blocked, system drawing
in air
Fault 00542 Needle lift

sender implausible signal
may be stored
- Check fuel system
Open circuit in wiring to

commencement of injection valve -N108
Engine clatters when idling as commencement of

injection constantly advanced
- Test commencement of
injection valve
page 23-29
Several faults may be

stored
- Test fuse
No constant commencement of injection possible

at Basic setting (display
block 2 varies over more
than 10 readouts)
poor performance
- Replace commencement
of injection valve
Commencement of injection valve -N108 worn
1)
Not available at present.
Edition 02.99
S00.5111.53.20
------------ 01-11 ------------
01
OCTAVIA
Self-Diagnosis

Fault number
old
Rectifying fault
new
00553
Possible effects
16485
Air mass meter -G70

Implausible signal
Engine was stalled (within

the last 50 starts)
- Erase fault memory, continue checking vehicle
Battery weak
Poor performance
Air mass constantly indicated in measured value
block
- Test battery
Sporadic open circuit in

wiring (cable break) to
needle lift sender -G80
Misfiring, jerking
Fault 00542 Needle lift
sender implausible signal
possible or open/short circuit to positive

page 23-42
Air filter blocked

Vacuum hoses of exhaust
gas recirculation incorrectly connected or mechanical EGR valve constantly open
Irregular idling, poor performance
- Inspect intake system

- Inspect vacuum hoses
page 23-37
Air mass meter faulty
Poor performance, jerking
- Test air mass meter

page 23-35
Reduced output
Black exhaust possible
when accelerating from
low revs
Open/short
circuit to earth
17552
-G70 faulty
short circuit to earth
Short circuit to positive
17553
-G70 faulty
Supply voltage
17554

short circuit
00575
17958
Intake manifold pressure

Control difference
if appropriate
Charge pressure
Control difference
Sudden drop in power

Reduced output
------------
Hoses wrongly connected,

not fitted on, blocked,
leaking
Turbocharger vacuum unit
faulty
Charge pressure control
solenoid valve -N75 faulty
------------
- Test charge pressure

page 23-22
- Inspect charge pressure
hoses page 23-27
Edition 02.99
S00.5111.53.20
Self-Diagnosis

old
00625
new
Possible effects
Line interruption between

speedometer sender -G22
and dash panel insert
-G22 defective
Speedometer -G21 defective
dash panel insert and engine control unit
CCS not operational

Air conditioning not operational
Possible load alteration
shock
Fault number
Glow period warning lamp

not operational
16885
Speed signal
Implausible signal
If necessary
Vehicle speed signal
Implausible signal
Vehicle speed signal
Signal too great
00626
17948
18024
Glow period warning lamp -K29

Short-circuit to
positive
to earth
00668
18025
Line interruption
Bulb defective

not operational
- Check speed signal

page 23-52
- Check speedometer
sender
Electrical System; Repair
Group 90
- Check glow period warning lamp

page 28-2
Diesel direct injection system relay -J322 jams

(safety deactivation)
- Test voltage supply for diesel direct injection system

page 23-38
E45 defective
Cruise control system not

operational
- Check cruise control system

page 23-55
- Reading measured value
block 6
page 01-35
Cruise control
system switch
-E45
Edition 09.03
S00.5111.55.20
Rectifying fault

lights up constantly
18009
Implausible signal
Undefined
switch status
01
Onboard voltage,
terminal 30
00671
OCTAVIA
------------ 01-13 -------------
01
OCTAVIA
Self-Diagnosis

Fault number
old
00741
Possible effects
Rectifying fault
new
-
Brake pedal monitoring

Switch incorrectly set
Open circuit in wiring
-F or -F47 faulty
Fuse faulty
Both brake lights faulty
00765
Preglow indicator lamp

flashes
- Test -F and -F47 and set

page 23-44
Fuse or brake light faulty
- Test fuse and brake light
10-pin connector for injection pump separated

Injection pump faulty
short circuit
Several faults stored

Engine stops
Drivability problems
Engine stops
- Inspect plug connection

of injection pump
- Test modulating piston
movement sender
page 23-45

-G79 faulty (idling switch)
Implausible signal
Speed governed to approx.

1100 rpm as safety measure
No throttle response
Preglow indicator light
flashes
Fast idling speed
- Test accelerator pedal position sender

page 23-47
Preglow indicator light

flashes
- Code control unit

page 01-23
17762
Modulating piston
movement sender
-G149
00777
18039
Accelerator pedal position sender -G79

Signal too large
Voltage supply
18040

short circuit
Implausible signal
as appropriate
18047

-G79 faulty (idling switch)
Accelerator pedal position sender 1/2

-G79+-G185 1)
Implausible signal
01044

-G79 faulty
18020
Engine control unit

incorrectly coded
Invalid control unit coding
1)
Incorrect fault text readout. The correct readout is:

Accelerator pedal position sender -G79
------------ 01-14 ------------
Edition 02.99
S00.5111.53.20
Self-Diagnosis
OCTAVIA
01
01117
Possible effects

AC generator and diesel
direct injection system
control unit -J248 AC generator defective
Voltage regulator on AC
generator defective
Auxiliary heater not operational
- Check wiring
Binder:
Electrical Fault Finding
and Fitting locations
- Check AC generator Repair Group 27; AC generator
block, display group 016
page 01-37
Short-circuit in the wiring
Reduced vehicle acceleration, when the air conditioning system is switched on
- Testing signals from/to the

air conditioning system
page 23-49.
Line interruption
new
Engine preheating not operational
Low heat output relay

-J359 defective
old
Fault number
Engine preheating is on
- Check wiring
Binder: Current Flow Diagrams, Electrical Fault
Finding and Fitting locations
- Check low heat output repage 01-18, Actualay
tor diagnosis
17911
Load signal for

generator tml. DF
Implausible signal
01180
Engine/air conditioning compressor electrical connection

Short-circuit to
positive
01193
19460
Low heat output

relay -J359
Line interruption
or short-circuit
to earth
Short-circuit to
positive
Edition 09.03
S00.5111.55.20
19459
Rectifying fault
------------ 01-15 -------------
01
Self-Diagnosis
OCTAV1A
01194
Rectifying fault
Line interruption
new
Possible effects
High heat output relay

-J360 defective
old
Fault number
Engine preheating is on
- Check wiring
Finding and Fitting Locations
- Check high heat output relay page 01-18, Actuator diagnosis
19462
High heat output

relay -J360
Line interruption
or short-circuit
to earth
Short-circuit to
positive
01237
19461
-N109 defective, leaking

or jammed
Reduced performance
Engine stoppage
-N109 defective
Line interruption or shortcircuit to earth
Engine stoppage
Reduced performance
Charge pressure too low
Reduced performance
Charge pressure too high
17945
Fuel shut-off
valve -N109
Mechanical fault
or
Malfunction
to earth
01262
17946
17954
- Check -N109 page

01-18, Actuator diagnosis
- Check wiring
Charge pressure
solenoid valve
-N75
Short-circuit to
positive
Short-circuit to
earth
to earth
------------ 01-16 -------------
17955
17957
Line interruption
Solenoid valve defective
- Check charge pressure

solenoid valve page
23-24
Reduced performance
Charge pressure too low
Edition 01.04
S00.5111.56.20

old
Fault number
01265
01
Self-Diagnosis
OCTAV1A
new
Possible effects
Rectifying fault
17810
Exhaust gas
recirculation valve
-N18
Short-circuit to
positive
to earth
01266
17849
Line interruption
Solenoid valve defective
No exhaust gas
recirculation
No exhaust gas
recirculation
Too much exhaust gas

recirculation
Reduced performance,
black smoke
Glow plug system not operational
18026
- Check exhaust gas recirculation valve -N18

page 23-24
Glow plug relay

-J52
Short-circuit to
positive
to earth
18027
Line interruption
Relay defective
01268
Injection pump defective,

leaking
Incorrect driving behaviour

Engine stoppage
17969
- Check glow plug relay

-J52

Metering adjuster
-N146
Control difference (deviation)
upper limit value
17970
lower limit value
17971
Edition 01.04
S00.5111.56.20
Metering mechanism adjusted

Metering mechanism adjusted
Jerking, poor performance
- Check metering adjuster

-N146 page 23-45
- Replace injection pump
page 23-8
Black smoke
Irregular engine running
------------ 01-17 -------------
01
Self-Diagnosis
old
Fault number
01269
new
Possible effects
OCTAV1A
Rectifying fault
17659
Commencement
of injection valve
-N108
Short-circuit to
positive
to earth
17660
Valve defective
Line interruption (fuse)

For vehicles
08.97
19561
Engine jerks when idling

because commencement
of injection is constantly
adjusted to advance.
Engine jerks when idling

because commencement
of injection is constantly
adjusted to advance.
- Check commencement of
injection valve
page 23-29
Possible that several faults

are stored
- Check fuse
Poor performance because commencement of

injection is constantly adjusted to late
- Check commencement of
injection valve
page 23-29
Hard engine knock
- Check Variable intake manifold flap change-over

valve -N239 page 23-57
01282
Variable intake
manifold flap
change-over
valve -N239
to earth
Short-circuit to
positive
------------ 01-17.1 -------------
19560
Line interruption
Variable intake manifold
flap change-over valve
defective
Edition 01.04
S00.5111.56.20

old
new
Possible effects
Rectifying fault
Sender for coolant temperature -G62 supplies

implausible signal caused
by loose contact or corrosion due to humidity in the
connector
Fault number
16500
01
Self-Diagnosis
OCTAV1A
Cold-start difficulties at
very low temperatures
Poor driveability during
warm-up
Increase in fuel consumption
Increased emission levels

block, display group 007
page 01-51
- Check -G62 page 23-43
Coolant temperature sender -G62

Implausible signal
Signal input in engine

control unit defective
(control unit defective
Coolant regulator defective (thermostat)
16955
- Replacing engine control

unit page 23-20
- Check coolant regulator
1.9 l/66 kW (TDI) Engine,
Mechanical Components;
Repair Group 19
Brake light defective

Brake light does not light
Line interruption or shortup
circuit to positive or earth
Engine speed fluctuations
between brake light switch
during braking
and engine control unit
- Check brake light switch

and brake pedal switch
page 23-44
Brake light switch

-F
Implausible signal
17811
Exhaust gas
recirculation system
Control deviation
Edition 01.04
S00.5111.56.20
Exhaust gas recirculation

valve -N18- defective

system not operational
- Check exhaust gas

recirculation solenoid
valve page 01-18,
Actuator diagnosis

potentiometer -G212- defective
Mixture adaptation not operational
- Check exhaust gas

recirculation valve
1.9 l/66 kW (TDI) Engine, Mechanical Components; Repair Group 26
------------ 01-17.2 -------------
01
Self-Diagnosis
old
Fault number
17931
new
Possible effects
OCTAV1A
Rectifying fault
Crash signal of
airbag CU
Implausible signal
17964
Fault in airbag system
Airbag warning light comes - Check airbag

on
Body Work; Repair Group
01
Fault in charge pressure

control
-N75 defective

Reduced performance

control solenoid valve
-N75 page 01-18,
Actuator diagnosis
control
Repair Group 21
Fault in charge pressure

control
-N75 defective

Reduced performance

control solenoid valve
-N75 page 01-18,
Actuator diagnosis
control
Repair Group 21
Cruise control system

switch defective
Line interruption
Cruise control system not

operational
- Check cruise control system page 23-54

block 6 page 01-35
Charge pressure
control
Regulating limit
not reached
17965
Charge pressure
control
Regulating limit
exceeded
17977
Cruise control
system switch
(CCS) -E45
Implausible signal
------------ 01-17.3 -------------
Edition 01.04
S00.5111.56.20

old
Fault number
17978
01
Self-Diagnosis
OCTAV1A
new
Possible effects
Rectifying fault
Engine control
unit blocked
Manipulation attempt
Start attempt with an
adapted ignition key
Engine control unit not
adapted to immobiliser
control unit
Engine starts and stops

immediately
Short-circuit in communication cable

Fault in the immobiliser
system
For vehicles
08.97
- Adapt engine control unit

to immobiliser
Binder: Electrical system;
Repair Group 90
- Check immobiliser
Binder: Electrical system;
Repair Group 90
Immobiliser control unit

defective/missing
Engine control unit
wrongly coded
- Code engine control unit

page 01-23
18034
Data bus drive

Missing message from transmission CU
18044
Databus lines to automatic transmission control

unit interrupted
Poor driveability (jerking

- Check data bus page
when changing gears, load
23-55.3
alteration shock etc.)
Databus lines defective

Fault in ABS system

23-55.3
Fault in airbag system
Warning light for airbag

comes on
Check airbag
Body Work; Repair Group
01
Fault in the system of the

automatic transmission
- Check automatic transmission control unit

Binder: Automatic transmission
Data bus drive

Missing message from
Airbag CU
18050
Read out fault

memory of airbag
control unit
Edition 01.04
S00.5111.56.20
------------ 01-17.4 -------------
01
Self-Diagnosis
old
Fault number
18058
new
Possible effects
OCTAV1A
Rectifying fault
Data bus drive

Missing message from instrument cluster
18061
Read out fault
memory of ABS
control unit
18062
No vehicle dynamics control - Check ABS control unit

TCS not operational
Binder: Chassis; Antilock
MSR not operational
Brake System
Oil level/oil temperature

sender -G266 defective
Warning light for oil level

comes on
- Check oil level/oil temperature sender -G266

Binder: Electrical System;
Repair Group 90
Short circuit in wiring
Reduced performance
- Check air conditioning

compressor engagement
page 01-18, Actuator
diagnosis
Read out fault

memory of instrument cluster
18065
Poor driveability
Fault in ABS control unit
Databus lines defective

Incorrect or defective
dash panel insert
Incorrect or defective engine control unit

23-55.3
Air conditioning
input/output
Short-circuit to
positive
18090
Data bus drive

Implausible signal from ABS
control unit
Databus lines to ABS con- No vehicle dynamics control unit interrupted

trol
TCS not operational
MSR not operational
Fault in ABS system
------------ 01-17.5 -------------

23-55.3
- Check ABS control unit
Binder: Chassis;
Antilock Brake System
Edition 01.04
S00.5111.56.20

old
Fault number
For vehicles
08.97
18259
01
Self-Diagnosis
OCTAV1A
new
Possible effects
Rectifying fault
18057
Data bus drive

Missing message from ABS CU
For vehicles
08.97
18262
Databus lines to ABS control unit interrupted
Fault in ABS system
No vehicle dynamics control

Binder: Chassis;
Antilock Brake System
18056
Data bus drive
Databus lines to auto Poor driveability

matic transmission or ABS
(jerking when changing
control unit interrupted
gears, load alteration
shock etc.)

23-55.3
Fault in automatic transmission or ABS system
Mixture adaptation not operational

Binder: Chassis; Antilock
Brake System
- Check automatic transmission control unit
Binder: Automatic transmission
Accelerator pedal position

sender -G79 defective
Hardware defective
Shifting points for automatic gearbox N.O.K.
- Check accelerator pedal

position sender -G79
page 23-47
Engine control unit internally defective
Poor driveability
Engine stoppage
Glow period indicator light
flashes
- Replace engine control

unit
page 23-20
or
defective
19458

23-55.3
Kick-down switch
F8
Implausible signal
65535
Control unit defective
Edition 01.04
S00.5111.56.20
16989
17795
18048
------------ 01-17.6 -------------
01
OCTAVIA
Self-Diagnosis
Actuator diagnosis
Performing actuator diagnosis
With the actuator diagnosis the following parts
are activated in the sequence indicated:
1. Commencement of injection valve (N108)
2. Exhaust gas recirculation valve (N18)
3. AC compressor engagement
4. Fuel shut-off valve (N109)
5. Charge pressure control solenoid valve
(N75)
6. Glow plug relay (J52)
7. Glow period warning lamp (K29)
8. Low heat output relay (J359) 1)
9. High heat output relay (J360) 1)
10. Fault lamp 2)
1)
2)
Only for vehicles with special equipment

For vehicles as of 08.03.
Test preconditions for vehicles with air conditioning

l Vehicle at room temperature
(at least + 15C)
l Air conditioning switched on
l Lowest temperature and highest blower

speed preselected
Special tools, aids and testers required

V.A.G 1551/3, 3A, 3B or 3C
Procedure
-
Vehicle system test

Select function XX
------------ 01-18 -------------
HELP

and select engine electronics control unit
(address word 01). The engine must be running in idle page 01-2).
Edition 09.03
S00.5111.55.20

03 - Final control diagnosis
Press keys 0 and 3 for the function Final

control diagnosis.
-
Final control diagnosis

Start of injection valve -N108
01
Self-Diagnosis
OCTAVIA
Confirm the entry with the key Q.
When the valve is actuated, this results in a

clearly audible change in the combustion
noise (diesel noise).
If no change in the combustion noise can be

heard:
EGR valve -N18
Test injection timing device control range

page 23-28.
Press the key.
The valve should click.
Note:
The clicking of the valve cannot be heard because of the engine noise and should therefore
be felt by touching.
If the valve does not click:
AC compressor cut-off
Test EGR valve
page 23-34.
Press the key.
What is tested is the AC compressor cutoff.
The test step is also displayed in the case of

vehicles without air conditioning.
The AC compressor should stop within 5

seconds (visual inspection with electric
torch), and then start and stop again approximately every 5 seconds.
If the AC compressor is not switched off:

-
Edition 05.97
S00.5111.51.20
Test AC compressor cut-off
page 23-49.
------------ 01-19 ------------
01
Self-Diagnosis

Fuel cut-off valve -N109
OCTAVIA
Press the key.
The engine should stop.
If the engine does not stop:
-
Switch off the ignition.
Unscrew fuel cut-off valve and clean any

metal swarf and dirt.
Repeat final control diagnosis; if the engine

again does not stop, replace fuel cut-off
valve.

Charge pressure control solenoid valve -N75
Press the key.
The solenoid valve should click.
Note:
It is very difficult to hear the clicking of the valve

and it should therefore be checked by touching.
If the solenoid valve does not click:
-

Glow plugs relay -J52
Test charge pressure control solenoid valve

page 23-24.
Press the key.
The relay should click.
Because of the high power consumption of

the glow plugs, it is also possible to check
that the relay switches on and off by observing how the interior light becomes dimmer
and then brighter.
If the relay does not click:

-

Glow period warning light -K29
Test glow plugs relay

Finding and Fitting Locations binder
Press the key.
The warning light should flash.
------------
------------
Edition 05.97
S00.5111.51.20
OCTAVIA
01
Self-Diagnosis
If the warning lamp does not flash:
-
Actuator diagnosis
Low heat output relay -J359
Check glow period warning lamp

page 28-2.
Press key.
The relay valve must click.
- Check low heat output relay:
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting locations.
-
Actuator diagnosis
High heat output relay -J360
Press key.
The relay valve must click.
- Check low high heat output relay:
Fault Finding and Fitting locations.
-
Actuator diagnosis
Fault lamp
Press key.
The fault lamp must flash.
If the fault lamp does not flash:
- Check fault lamp
Fault Finding and Fitting locations
-
Vehicle system test

Select function XX
HELP
Press key.
-

confim entry with key Q.
Basic setting
Test conditions
l Coolant temperature at least 80 C
l Electrical consumers must be disconnected
(the radiator cooling fan must be off during
this test)
l Air conditioning switched off
Edition 09.03
S00.5111.55.20
------------ 01-21 -------------
01
OCTAVIA
Self-Diagnosis

V.A.G 1551/3A, 3B or 3C.
Procedure
-
Vehicle system test

Select function XX
HELP
Basic setting
Enter display group number XXX
HELP
-
System in Basic setting

1
2
3
4
5
10
Enter 04 for the function Basic setting and

-

(address word 01). The engine must be running in idle.
(Connect vehicle system tester and select
engine electronics control unit page 01-2).
Enter 000 and confirm entry with the key Q.
(1... 10 = Display fields)
Display group 000 in idle (warm engine, coolant temperature not below +85 C)
This display group serves as a dynamic test of the commencement of injection. The commencement of injection valve
(N108) is constantly actuated, so that the injection timing device is retarded.
System in Basic setting
42
46
20
0
90
201
64
153 127
83
Ignore
Fuel temperature: at approx. 40 C (if the temperature is not reached at

a low outside temperature, ignore specified value)
Ignore
Coolant temperature: approx. 90 C
Ignore
Ignore
Ignore
Accelerator pedal position: 0
The commencement of injection is dependent on the fuel temperature,

specified values
page 23-13, Dynamically test and set commencement of injection
Idling speed: 41...441)
1)
For vehicles 07.97 = 41...44

For vehicles 08.97 = 42...45
For vehicles 05.99 = 43...46
------------ 01-22 -------------
Edition 09.03
S00.5111.55.20
OCTAVIA
01
Self-diagnosis
Coding control unit

If the code which is displayed does not match
the vehicle, or if the control unit has been replaced, it is then necessary to code the control
unit as follows.
V.A.G 1551/3, 3A, 3B or 3C
Test procedure
-

Select function XX
HELP
-
Code control unit

Enter code number XXXXX
Q
(0-32000)

and select engine electronics control unit (address word 01). The ignition must be switched on for this step page 01-2.
Enter 07 for the function Code control unit

and confirm the entry with the key Q.
-
Enter the relevant code number for this vehicle and confirm the entry with the key Q.
Coding control units
Code
number
00001
00002
Models 07.97
Models fitted with
Code
number
Automatic gearbox
00001
Models 08.97
Manual gearbox
00002
00003
00005
038906018.. 1.9l R4 EDC G00SG 1822
Coding 00002
WSC 01234
Models fitted with

Automatic gearbox
Manual gearbox with activated CAN

databus (models with ABS)
Manual gearbox for 4x4 models
Manual gearbox without CAN databus

(models without ABS)
K The control unit identification is shown in the

display (example):
-
Switch ignition off and on again.
Notes:
The code entered is activated when the ignition is switched on again
If the ignition is not switched off and on again

after entering the valid code, it is then not
possible to erase the fault 01044 Control unit
incorrectly coded.
-
Edition 12.00
S00.5111.54.20
Press key.
------------ 01-23 ------------
01
Vehicle system test

Select function XX
Self-Diagnosis
HELP
OCTAV1A
K Read-out on display
-

Readiness code
Valid for vehicles 08.03
Reading readiness code

Function
The readiness codes are two 8-digit numerical
codes which indicate the status of the
emission-relevant diagnoses.
If the diagnosis for a system was successfully
performed (e.g. exhaust gas recirculation system), the relevant position of the numerical code
is set from 1 to 0.
This diagnosis is performed at regular intervals
during normal driving. After repairs have been
carried out to an emission-relevant system, it is
recommended to generate the readiness code
in order to thus ensure that the systems operate properly. If a fault is detected during diagnosis, it is then stored in the
fault memory.
The readiness code is erased through deletion
of the fault memory, that is all relevant points
will be set to 1.
Generation of the readiness code means to activate the diagnostic functions such as diagnosis of fuel supply, diagnosis of other systems
etc.
Procedure
Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3C-
------------ 01-24 -------------
Connect vehicle system tester -V.A.G 1552and enter address word 01 Engine electronics, ignition switched on page 01-24.
Edition 01.04
S00.5111.56.20
01
Self-Diagnosis
OCTAV1A
Reading measured value block

00000000 00000110 10000000
17
00000000
Read function 08 Reading measured value

block and select display group 017.
K Read-out on display
Meaning of 8-digit numerical block for readiness code in display field 2

1
7
1
Ignore
Meaning
Ignore
Ignore
Ignore
Ignore
Diagnosis of other systems
Diagnosis of fuel supply

Ignore
Meaning of 8-digit numerical block for readiness code in display field 4

1
Edition 01.04
S00.5111.56.20
7
0
Ignore
Meaning
Ignore
Ignore
Ignore
Ignore
Ignore
Ignore
Diagnosis of exhaust gas recirculation system
------------ 01-25 -------------
01
Self-Diagnosis
OCTAV1A
If the specified values are not reached, generate readiness code page 01-26.
Press key.
Enter function 06 End output and switch

off ignition.
Generating readiness code

Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3CTest conditions
l All electrical consumers such as e.g. light
and rear window heater must be switched
off.
l Intake air temperature below 60 C display group 007, display field 3
l Coolant temperature at least 83 C display group 007, display field 4
Procedure
-
Connect vehicle system tester -V.A.G 1552and enter address word 01 Engine electronics, ignition switched on page 01-2.
Note:
Certain steps must be carried out twice, in order to achieve the readiness code.
Work step 1:
X fault detected
Interrogating fault memory
Enter function 02 Interrogating fault memory and confirm entry with key Q.
K The number of stored faults or No fault detected appears in the display.

If a fault is stored:
-

page 01-8.
-
------------ 01-26 -------------
Press.
Edition 01.04
S00.5111.56.20
OCTAV1A
Work step 2:
Vehicle system test
Fault memory is erased
01
Self-Diagnosis
K-
Erasing fault memory
Enter function 05 Erasing fault memory and

confirm entry with key Q.
Note:
Readiness code is erased each time the fault

memory is erased.
If the ignition is switched off during Interrogating fault memory and Erasing Fault memory,
the fault memory is not erased.
-
Press.
Work step 3:
-
Switching off ignition
Wait at least 5 seconds with ignition OFF.
Note:
This point is important, because with certain diagnoses the slowing down of the control unit
must be ended. Otherwise readiness code cannot be generated.
Work step 4:
-
Switching on ignition
Charge pressure sender is adapted with atmospheric charge pressure sender.

Work step 5: 1st test of fuel supply and
other systems
1
2500/rpm
4.6 mg/h
2.0 CA
94.2 C
Start engine.
Select function Reading measured value
block and display group 001.
K-
For 5 seconds increase the engine speed to

2500 rpm and then run engine at idling
speed.
Work step 6:
culation
1
1650/rpm
4.1 mg/h
4.0 CA
93.2 C
K-
1st test of exhaust gas recir-
Increase engine speed to 1600 rpm up to

1700 rpm and maintain it for at least 10 seconds in this range.
In this speed range, the exhaust gas recirculation is active and the control difference is
checked. (Condition for readiness code to generate exhaust gas recirculation).
Edition 01.04
S00.5111.56.20
------------ 01-27 -------------
01
Self-Diagnosis
Work step 7:
-
Switching off ignition
Work step 8:
-
OCTAV1A
Switching on ignition
Wait at least 10 seconds with ignition ON.
Work step 9: 2nd test of fuel supply and

other systems
1
2500/rpm
4.6 mg/h
2.0 CA
94.2 C
Start engine.
Select function Reading measured value
block and display group 001.
K-
For 5 seconds increase the engine speed to

2500 rpm and then run engine at idling
speed.
Work step 10: 2nd test of exhaust gas recirculation

1
1650/rpm
4.1 mg/h
2.0 CA
93.2 C
K-
Increase engine speed to 1600 rpm up to

1700 rpm and maintain it for at least 10 seconds in this range.

17
00000000 00000110 10000000
00000000
Press C.
Enter 017 for display group 017 and read
readiness code.
K Specified value in display field 2:

00000110
Specified value in display field 4:
000000000
-
------------ 01-28 -------------
Press.
If the specified values are not reached, repeat procedure for generating readiness
code page 01-26.
Edition 01.04
S00.5111.56.20
OCTAV1A
01
Self-Diagnosis
Work step 11: Interrogating fault memory

X fault detected!
Enter function 02 Interrogating fault memory and confirm entry with key Q.
K The number of stored faults or No fault detected appears in the display.

If a fault is stored:
-

page 01-8 and re-generate the readiness
code page 01-26.
17
00000000
00000110
10000000
Edition 01.04
S00.5111.56.20
00000000
Press.
K Readiness code was successfully generated, if

no fault is stored after two work sequences of
the test procedure in the fault memory for the
engine control unit and if the following display
appears in the channel 017.
------------ 01-28.1 -------------
01
Self-Diagnosis
OCTAVIA
Measured value blocks

Test conditions
l Coolant temperature at least 80 C
l Electrical consumers must be disconnected
(the radiator cooling fan must be off during
this test)
l Air conditioning switched off
l No fault in fault memory
Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3C-.
Procedure
-
Vehicle system test

Select function XX
HELP

Enter display group number XXX
HELP

and select engine electronics (address word
01). The engine must be running in idle.
-
Enter 08 for the function Read measured

value block and confirm entry with the key
Q.
-
Enter the desired display group number and

Note:
Display group number 000 is an example to represent the sequence.
1
2
3
4
5
6
Vehicle system test
Select function XX
------------ 01-28.2 -------------
10
HELP
K Read-out on display, e.g.:

-
Press key.
-
Enter 06 for the function End output and

Edition 09.03
S00.5111.55.20
OCTAVIA
01
Self-diagnosis
Specified readouts for general vehicle check
Display group 000, engine idling (engine warm, coolant temperature not less than +85 C)
for models 07.97
Read measured value block
42
50
20
90
201
64
153
127
83
K Readout in display
Inducted air mass 70...110 o.k.

if not within tolerance
page 01-49, display group 003
Fuel temperature: no specification
Intake manifold temperature: no specification
Coolant temperature: 80...51 o.k.

> 80: warm up engine
Ambient air pressure: no specification
Charge pressure: ignore
Injected quantity: 10...30 o.k.

Commencement of injection: 20...60 o.k.

Idling speed: 41...44 o.k.

Edition 12.00
S00.5111.54.20
------------ 01-29 ------------
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Self-diagnosis
for models 08.97 04.99
42
50
20
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201
64
153
127
83
Inducted air mass
not
tolerance
display
003
Intake
up
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not
pedal
is
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not
tolerance
tolerance
measured values apply

in
speed
------------
1
tolerance
display
display
display
001
004
002
recirculation system is
about 2 minutes; necessary
blip
or
recirculation
Edition 12.00
S00.5111.54.20
OCTAVIA
01
Self-diagnosis
for models 05.99
43
50
20
90
201
64
153
127
83
Inducted air mass 1) 69...110 o.k.

Fuel temperature: 91...201
Intake manifold temperature: 190...80

Ambient air pressure: ignore
Charge pressure: ignore
Injected quantity: 15...45 o.k.

Commencement of injection: 12...75 o.k.

Idling speed: 43...46 o.k.

1)
The measured values apply when the exhaust gas recirculation system is switched on. The exhaust gas recirculation
is switched off in the idling speed range after about 2 minutes; if necessary briefly blip throttle or re-start engine.
Edition 12.00
S00.5111.54.20
------------ 01-31 ------------
01
OCTAVIA
Self-diagnosis
Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +85 C)
for models 07.97
Notes:
Accelerate the vehicle at full throttle for the test.
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person
required).
Read measured value block 0
186
225
255
186
186
201
64
138
175
233
Inducted air mass: > 210 o.k.

< 210
Fuel temperature: no specification
Intake manifold temperature: no specification

Ambient air pressure: ignore
Charge pressure: 171...191 o.k.

Injected quantity: 170...195 (full load injected quantity) o.k.

125: emergency injected quantity, system fault detected
Accelerator pedal: 255 (depressed fully)
page 01-5, Interrogating fault memory
Commencement of injection: 180...245 (dependent on engine speed)

page 01-42, Display group 004
Engine speed: 160...190 (do not exceed 4000 rpm, engine speed is governed)
------------ 01-32 ------------
Edition 12.00
S00.5111.54.20
OCTAVIA
01
Self-diagnosis

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speed 2900...3100 rpm) for models 08.97 04.99
Notes:
required).
Read measured value block 0
205
255
201
175
255
Inducted air mass: 255
255
temperature:
display
010
Intake manifold temperature:
Coolant temperature:
up
air pressure:
pressure:
if not
tolerance
Injected quantity:
125:
(full load injected quantity)

injected quantity system fault detected
pedal: 255 (depressed fully)
Commencement of injection:
if not
tolerance
speed:
Edition 12.00
S00.5111.54.20
display
(dependent on
Display
011
fault memory
speed)
------------ 01-33 ------------
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OCTAVIA
Self-diagnosis
Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80
engine
Notes:
required).
205
255
201
175
255
Inducted air mass: 255
255
temperature:
display
010
Intake manifold temperature:
Coolant temperature:
up
air pressure:
pressure:
if not
tolerance
Injected quantity:
125:
(full load injected quantity)

injected quantity system fault detected
pedal: 255 (depressed fully)
Commencement of injection:
if not
tolerance
speed:
------------
------------
display
(dependent on
Display
011
fault memory
speed)
Edition 12.00
S00.5111.54.20
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S00.5111.54.20
------------
------------
pedal depressed
pedal depressed
point
operated
to
Cruise
operating state of
pedal depressed
pedal depressed
Display
(CCS)
pedal and brake pedal depressed
pedal depressed
pedal
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01
Self-diagnosis
OCTAVIA

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01
Self-diagnosis
OCTAVIA
state
0
1
2 5 5
------------
state
Model fitted with CCS - CCS switched off

Model fitted with CCS - CCS switched on
Model without CCS, CCS function is not activated in engine control unit
------------
Edition 12.00
S00.5111.54.20
01
Self-diagnosis
Display group 016, engine idling

70.0 %
OCTAVIA
10000001
00
16
13.8 V
Supply voltage of control unit: ignore
Actuation of heating elements
Operating state of auxiliary heater
Generator load: ignore
Analysis: Table 1, operating state of auxiliary heater

Meaning if readout places = 1
x
1
1)
page 01-37, Table 1
Auxiliary heater switched off because:
page 01-37, Table 2
Coolant temperature greater than 70...80 C1) or intake air temperature

greater than 5 C
Alternator faulty
Battery voltage less than 9 V
Models 07.97 - engine speed less than 800 rpm

Models 08.97 04.99 - engine speed less than 875 rpm
Models 05.99 - engine speed less than 861 rpm
Engine start within the last 10 seconds
Coolant temperature sender (G62) or

intake manifold temperature sender (G72) faulty
Ignore
Ignore
If the intake air temperature at engine start is 5 C, the auxiliary heater is then switched off once the coolant
temperature reaches 70 C. If the air temperature is -10 C, however, the auxiliary heater is not switched off until the
coolant temperature is 80 C.
Analysis: Table 2, actuation of heating elements

x
1
Meaning if display places = 1
x
1
Actuation of heating elements
Low heating capacity relay (J359), switched on
High heating capacity relay (J360), switched on
Edition 12.00
S00.5111.54.20
------------ 01-37 ------------
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Edition 12.00
S00.5111.54.20
o.k.
cold
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cold
o.k.
o.k.
for models 07.97
Specified readouts for injection pump

01
Self-diagnosis
OCTAVIA
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S00.5111.54.20
load
------------
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cold
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load
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01
Self-diagnosis
OCTAVIA
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resistance in cable connection

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control
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------------
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Edition 12.00
S00.5111.54.20
cold
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cold
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blocked
valve
engine idling
not less than +80 C)
valve
cold
valve
blocked
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------------
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Edition 12.00
S00.5111.54.20
leaks
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test in
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Self-diagnosis
+80
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Edition 12.00
S00.5111.54.20
------------
------------
leaks
valve
blocked
block
valve
valve
required).
Notes:
Display group
test in
at full
or
gear
not less
engine
01
Self-diagnosis
OCTAVIA
01
OCTAVIA
Self-diagnosis
Specified readouts for engine idling
900 rpm
0.0 %
010
88.4 C
Coolant temperature
85...100 C o.k.
< 85 C:
warm up engine
Engine operating state
Engine speed
Table of engine operating state, page 01-46
Accelerator pedal position

0.0 % o.k.
> 0.0 % Accelerator pedal position sender incorrectly set or faulty
page 01-38; display group 001
page 23-47
Analysis: display of engine operating state

x
x
1
Meaning if display places = 1
x
1
Engine operating state
AC signal
switch off air conditioning
v o.k.: (idling speed switch closed)
Idling speed increased:

if AC switched on
switch off air conditioning
test brake
if accelerator and brake detected
pedal switch
if coolant auxiliary heater switched on
warm up
engine
------------ 01-46 ------------
Edition 12.00
S00.5111.54.20
OCTAVIA
01
Self-diagnosis
for models 07.97
The fuel injection system features a smooth idling control. It is able to detect differences in performance between the
individual cylinders (parts tolerances, injector flow, compression, etc.) and to compensate for these by selective
metering of the quantity of fuel injected in the idling speed range.
Such differences are detected in the idling speed range on the basis of the signal supplied by the engine speed
sender, which supplies four signals for each crankshaft revolution to the control unit. If the signals are received in the
same rhythm, all the cylinders are performing the same work. If one cylinder has a weaker performance, the crankshaft requires a longer time for the next half crankshaft revolution. In contrast, a cylinder with a stronger performance accelerates the crankshaft to such an extent that it requires a shorter time.
If the control unit has detected a variation, the cylinder in question is immediately supplied with a greater or lesser
injected quantity until the engine is again running smoothly.
What is shown in the measured value block is the variation of the injected quantity of the individual cylinders in
comparison to cylinder 3, which is necessary to achieve smooth engine idling.
+... mg/H: The relevant cylinder has a weaker performance than cylinder 3 and is therefore supplied with more fuel.
- ... mg/H: The relevant cylinder is stronger in performance than cylinder 3 and is therefore supplied with less fuel.

0.82 mg/H
-0.12 mg/H
0.49 mg/H
13
No readout
Variation of injected quantity of cylinders 4, 2, 1 to cylinder 3

-1.5 mg/H...+1.5 mg/H o.k.
All display blocks are too large: cylinder 3 strong
All display blocks are too small: cylinder 3 weak
Variation of injected quantity of cylinder 1 to cylinder 3
-1.5 mg/H...+1.5 mg/H o.k.
> +1.5 mg/H: cylinder 1 weak
< -1.5 mg/H: cylinder 1 strong

-1.5 mg/H...+1.5 mg/H o.k.

-1.5 mg/H...+1.5 mg/H o.k.
------------
Edition 12.00
S00.5111.54.20
------------
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OCTAVIA
Self-diagnosis
engine idling (engine
models
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The fuel injection system features a smooth idling control. It is able to detect differences in performance between the
individual cylinders (parts tolerances, injector flow, compression, etc.) and to compensate for these by selective
metering of the quantity of fuel injected in the idling speed range.
Such differences are detected in the idling speed range on the basis of the signal supplied by the engine speed
sender, which supplies four signals for each crankshaft revolution to the control unit. If the signals are received in the
same rhythm, all the cylinders are performing the same work. If one cylinder has a weaker performance, the crankshaft requires a longer time for the next half crankshaft revolution. In contrast, a cylinder with a stronger performance accelerates the crankshaft to such an extent that it requires a shorter time.
If the control unit has detected a variation, the cylinder in question is immediately supplied with a greater or lesser
injected quantity until the engine is again running smoothly.
- ...
The relevant cylinder has a weaker performance than cylinder
The relevant cylinder is stronger in performance than cylinder
measured value
and is therefore supplied with more fuel.

and is therefore supplied with less fuel.
in display
Idling controller - injected quantity cylinder
o.k.
cylinder weak
cylinder strong
o.k.
cylinder weak
cylinder strong
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------------
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Self-diagnosis
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readouts
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Self-diagnosis
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It is not possible to state specifications for the temperatures.
If the engine is cooled down, the temperature readouts for fuel, intake manifold and coolant are by necessity approximately identical with the ambient temperature. If one of the readout differs significantly, it is then necessary to
test the appropriate sensor.
Edition 12.00
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------------
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Edition 12.00
S00.5111.54.20
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------------
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mass
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07.97
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Self-diagnosis
OCTAVIA
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Edition 12.00
S00.5111.54.20
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Self-diagnosis
engine
OCTAVIA
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Edition 12.00
S00.5111.54.20
mass
------------
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value
mass
or
block
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or
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test in
Display group 010 at full
or
gear coolant t
not less
+80
engine
01
Self-diagnosis
OCTAVIA
01
Self-diagnosis
OCTAVIA
Specified readouts for charge pressure control
Display group 011 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +85 C)
for models 07.97
Notes:
required).
3340 rpm
1830 mbar
1850 mbar
11
68 %
On/off ratio (actuation) of charge pressure control solenoid valve

-N75
Momentary charge pressure

as specified charge pressure in display block 2 (tolerance 100 mbar) o.k.
insufficient charge pressure:
test, page 23-22
- No charge pressure control
excessive charge pressure:
- Pressure hose of charge pressure control dropped off or blocked, solenoid
test charge pressure, page 23-22
valve -N75 jamming
- Linkage at turbocharger rusted tight, pressure unit faulty
test charge
pressure, page 23-22
Specified charge pressure requested by control unit

1800...2050 mbar o.k.
> 2050 mbar charge pressure increased by tuning
Engine speed 2800...3200 rpm o.k.
------------ 01-58 ------------
Edition 12.00
S00.5111.54.20

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01
Self-diagnosis
Display group 011 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80 C, engine
speed 2900...3100 rpm) for models 08.97 04.99
Notes:
required).
rpm
mbar
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mbar
ratio
pressure
mbar
must
mbar
icient
pressure control
solenoid valve
at
speed
Edition 12.00
S00.5111.54.20
pressure control solenoid valve
display block
pressure control dropped

test
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pressure unit
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Self-diagnosis
011 at
test in
not less
+80
engine
Notes:
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rpm
mbar
11
mbar
ratio
speed
------------
------------
pressure control solenoid valve
pressure
mbar
must
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o c
display block
tolerance
pressure control dropped o or

test
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pressure
by control unit
mbar
mbar
pressure increased by
rpm
Edition 12.00
S00.5111.54.20
OCTAVIA
23
Fuel Preparation/Fuel Injection
Servicing diesel direct injection system

Safety precautions
Pay attention to the following precautions in order to avoid injuries to persons and/or damage
to the fuel injection and glow plug system:
Do not disconnect and connect the cables
of the glow plug and fuel injection system also not of test equipment - unless the ignition is switched off.
To operate the engine at starting speed without it actually starting, e.g. for testing the
compression pressure, unplug the connector at the injection pump.
Before disconnecting the battery, determine
the code of radio sets with anti-theft coding.
The ignition should always be switched off
before disconnecting and connecting the
battery otherwise the diesel direct injection
system control unit may be damaged.
Rules for cleanliness

Pay careful attention to the following 5 rules
for cleanliness when carrying out work on the
fuel supply/fuel injection system:
Thoroughly clean connection points and the
surrounding area before disconnecting.
Place removed parts down on a clean surface and cover over. Do not use fluffing
cloths!
Carefully cover over or seal opened components if repairs are not carried out immediately.
Install only clean parts:
Do not remove replacement parts from their
wrapping until just before installing.
Do not use parts which have been stored
unwrapped (e.g. in tool boxes etc.).
If the system is opened:
Avoid working with compressed air, if possible.
Avoid moving the vehicle, if possible.
In addition, ensure that no diesel fuel flows
onto the coolant hoses. If this happens, it is
then necessary to clean the hoses again
without delay. Replace any hoses which have
suffered damage.
Edition 05.97
S00.5111.51.20
------------ 23-1 ------------
23
Fuel Formation / Fuel Injection
OCTAVIA
Summary of fitting locations 07.97
Components A to E are not shown on the summary illustration.

A - Relay for diesel direct injection system (J322)
Electrical centre page 23-2.1, Fig. 1
B - Glow plug relay (J52)
Electrical centre page 23-2.1, Fig. 1
D - Brake light switch (F) and brake pedal

switch (F47)
Combined in a housing
In footwell at brake pedal page
23-2.1, Fig. 1
E - Clutch pedal switch (F36)
In footwell at clutch pedal page
23-2.1, Fig. 1
C - Accelerator pedal position sender

(G79)
In footwell at accelerator pedal
page 23-6
------------ 23-2 ------------
Edition 03.98
S00.5111.52.20
OCTAVIA
1 - Mechanical exhaust gas recirculation

valve
2 - Injection nozzle with needle lift sender
(G80)
3 - Diesel direct injection system control
unit (J248)
With altitude sender (F96)
4 - Electromagnetic EGR valve (N18)
5 - Charge pressure control solenoid
valve (N75)
6 - Air mass meter (G70)
7 - High heating capacity relay (J360)
Only for models with optional equipment
8 - Low heating capacity relay (J359)
9 - Coolant temperature sender (G62)
10 - Engine speed sender (G28)
23

11 - Plug connection
2-pin
For needle lift sender (G80)
3-pin
For engine speed sender (G28)
10-pin
For fuel temperature sender (G81)
For quantity adjuster (N146)
For modulating piston movement
sender (G149)
For commencement of injection valve
(N108)
For fuel cut-off valve (N109)
14 - Commencement of injection valve
(N108)
15 - Fuel cut-off valve (N109)
16 - Fuel metering control of injection
pump
With fuel temperature sender
With quantity adjuster (N146)
With modulating piston movement
sender (G149)
17 - Intake manifold pressure sender (G71)
and intake manifold temperature
sender (G72)
K Fig. 1
Components in footwell
1 - Glow plug relay (J52)

2 - Diesel direct injection system relay (J322)
3 - Clutch pedal switch (F36)
4 - Brake light switch (F) and brake pedal
switch (F47)
Edition 03.98
S00.5111.52.20
------------ 23-2.1 ------------
23
Fuel Formation/Fuel Injection
OCTAVIA
Overview of fitting locations 08.97 07.00
Components A to E are not shown in the illustration.

A - Diesel direct injection system relay
(J322)
electrical centre page 23-3, Fig. 2
B - Glow plug relay (J52)
electrical centre page 23-3, Fig. 2
D - Brake light switch (F) and brake pedal

switch (F47)
combined in a housing
in footwell at brake pedal page
23-3, Fig. 2
E - Clutch pedal switch (F36)
in footwell at clutch pedal page
23-3, Fig. 2
C - Accelerator pedal position sender

(G79)
in footwell at accelerator pedal page
23-6
------------ 23-2.2 ------------
Edition 12.00
S00.5111.54.20
OCTAVIA
23
1 - Intake fitting
With mechanical exhaust gas recirculation valve
With intake manifold flap
2 - Intake manifold flap changeover valve
(N239)
(G80)
unit (J248)
With altitude sender (F96)
5 - Electromagnetic EGR valve (N18)
6 - Charge pressure control solenoid
valve (N75)

2-pin
For needle lift sender (G80)
3-pin
For engine speed sender (G28)
10-pin
For fuel temperature sender (G81)
For quantity adjuster (N146)
For modulating piston movement
sender (G149)
For commencement of injection valve
(N108)
For fuel cut-off valve (N109)
(N108)
16 - Fuel cut-off valve (N109)
17 - Fuel metering control of injection
pump
With fuel temperature sender
With quantity adjuster (N146)
With modulating piston movement
sender (G149)
and intake manifold temperature
sender (G72)
K Fig. 2

switch (F47)
Edition 03.98
S00.5111.52.20
------------ 23-3 ------------
23
OCTAVIA
Overview of fitting locations 08.00
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Components A to E are not shown in the illustration.
light switch
and brake
switch
combined in a housing
in footwell at brake pedal
page 23-3.2, Fig. 3
direct injection
electrical centre page 23-3.2, Fig. 3
electrical centre page 23-3.2, Fig. 3
switch
in footwell at clutch pedal
page 23-3.2, Fig. 3
sender
in footwell at accelerator pedal page

23-6
------------ 23-3.1 ------------
Edition 12.00
S00.5111.54.20
OCTAVIA
23
1 - Mechanical exhaust gas recirculation

valve
with intake manifold flap
2-pin
for needle lift sender (G80)

(N239)
3-pin
for engine speed sender (G28)

(G80)
4 - Heated crankcase ventilation (N79)
only models with optional equipment
unit (J248)
with altitude sender (F96)
6 - Electromagnetic exhaust gas recirculation valve (N18)
7 - Charge pressure control solenoid valve (N75)
10-pin
for fuel temperature sender (G81)
for quantity adjuster (N146)
for modulating piston movement sender (G149)
for commencement of injection valve
(N108)
for fuel shut-off valve (N109)
(N108)
18 - Fuel shut-off valve (N109)
19 - Fuel metering control of injection pump
with fuel temperature sender (G81)
with quantity adjuster (N146)
with modulating piston movement
sender (G149)
and intake manifold temperature sender (G72)
12 - Vacuum unit
K Fig. 3


switch (F47)
Edition 12.00
S00.5111.54.20
------------ 23-3.2 ------------
23
OCTAVIA
Servicing injection pump
Pay attention to safety precautions

page 23-1
Pay attention to rules for cleanliness

page 23-1
Note:
Fuel hoses at the engine must be secured only

with spring-strap clips. It is not permitted to use
clamp-type or screw-type clips.
Removing and installing injection pump

page 23-8
1 - Stretch bolt
Always replace
20 Nm + 1/4 turn (90)
Dynamic test and setting of start of injection

page 23-13
2 - Injection pump gear

3 - Hub nut
On no account slacken
------------
------------
Edition 05.97
S00.5111.51.20
W
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OCTAVIA
23
for feed line

28 Nm
13
replace
Fuel
20 Nm
for cylinder 3 with needle lift sender

removing and installing, testing
page 23-16
tighten screw for return-flow line of
cylinder 3 to 10 Nm
for return-flow line

28 Nm
to control valve/fuel filter
10 Injection
tighten to 25 Nm
use ring wrench, e.g. 3035, for removing injection lines
always remove complete set of lines
11
45 Nm
12
20
21
22
23
2
2
Note:
Fuel hoses at the engine must be secured only

with spring strap clips. It is not permitted to use
collar-type or screw-type clips.
1
to fuel tank
2 Feed line
from fuel tank
do not mix up, blue ring at top
fitting location: arrow points toward

fuel tank
if filter replaced, remove retaining
clamp and take off control valve with
fuel lines connected
passage to filter opened at temperature below +15 C
passage to filter closed at temperature above +31 C
Edition 12.00
S00.5111.54.20
------------
------------
23
OCTAVIA
1 - Retaining clip
2 - Return line
from injection pump
3 - Feed line
to injection pump
4 - Fuel filter
the direction of flow is marked by arrows
for removing loosen clamping screw
at bracket
do not mix up connections
replace if damaged
fill up with diesel fuel before installing
5 - Gasket
replace if damaged
6 - Drain plug
to ventilate remove the retaining clip
of the preheating valve and remove
preheating valve with the fuel lines
connected, loosen clamping screw
and pull the filter upwards
release and drain approx. 0.1 litre fluid
Assembly overview of throttle

mechanism
For vehicles 07.98
1 - Allan screw
10 Nm
2 - Accelerator pedal position sender

(G79)
inspecting page 23-47
setting page 23-7
3 - Pulley
4 - Spring washer
5 - 10 Nm
6 - Thread cage
7 - Pedal bracket
------------ 23-6 ------------
Edition 09.03
S00.5111.55.20
E
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OCTAVIA
23
racket
pedal
testing page 23-47

pedal
accelerator pedal
and

V.A.G 1551/3, 3A, 3B or 3C
Hand-held multimeter, e.g. V.A.G 1526A
Test box V.A.G 1598/22
If the sender has been removed:
K-
Install cable pulley in position shown.
Edition 12.00
S00.5111.54.20
Install sender with preassembled cable pulley.

page 01-2.
------------
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S00.5111.54.20
(G79)
00
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23
OCTAVIA
OCTAV1A
23
Disassembling and assembling air filter
1 - Air mass meter -G70

inspecting page 23-35.
2 - Gasket ring
3 - Air filter top part
4 - 6 Nm
5 - Air guide
in air filter top part guide
Edition 01.04
S00.5111.56.20
6 - Filter element
7 - 10 Nm
8 - Air filter bottom part
9 - Air guide
10 - 6 Nm
------------ 23-7.2 ------------
23
OCTAV1A
Removing and installing injection

pump
Adjusting straightedge MP 1-312
Adjusting device for TDC MP 1-313
Rig pin 3359
Counterholder MP 1-216
Key for the timing belt tensioner (e.g. Matra
V159, Hazet 2587, Stahlwille 127-17)
Connection fitting e.g. V.A.G 1318/10
Vacuum pump (e.g. V.A.G 1390)
Torque
Ring spanner for injection lines (e.g. 3035)
Puller T40001 with hooks T40001/2 and
T40001/3
Feeler gauges
If necessary steel straightedge (tear-off tool)
Transparent plastic line
Removing
-
Remove right headlight Electrical System;

Repair Group 94
Remove engine cover.
Remove all the fuel lines from the injection

pump.
Note:
Use the open ring spanner e.g. 3035 for removing high pressure lines.
-
Remove plug from the intake manifold pressure sender and the intake temperature
sender.
------------ 23-8 ------------
Cover the openings with a clean cloth.
Remove air guide pipe between charge air

cooler and intake pipe.
Edition 01.04
S00.5111.56.20
OCTAVIA
23
Remove the top toothed belt guard, the

vacuum pump and the cylinder head cover.
Remove sound-absorbing pan and air guide

pipe between intercooler and turbocharger.
Engine installed
K-
Take off cover at inspection opening.

Position the crankshaft to TDC of cylinder 1
-arrow-.
Engine placed down on floor

K-
Screw in setting device for TDC point (MP

1-313, as shown in the illustration.
Set setting device to 96 mm -arrow- (the left

notch of the vernier -arrow A- is the reference point).
Rotate crankshaft until TDC marking -arrow

B- on the flywheel is aligned with the edge of
the setting device.
Engine attached to engine holder MP 1-202
Edition 03.98
S00.5111.52.20
Position flexible steel ruler (marking tool)

against the circumference of the flywheel.
Measure exactly 100 mm from the TDC
marking -arrow A- and make a mark -arrow
B- as an aid with marking tool.
------------
K-
------------
23
OCTAVIA
K-
Screw in adjusting device for TDC MP 1-313

as shown in illustration.
Set adjusting device to 91.4 mm (the lefthand notch of the vernier -arrow A- is the
reference point).
Rotate crankshaft until the help marking on

the flywheel is aligned with the edge of the
adjusting device -arrow B-.
For all cases

K-
Lock the camshaft with the adjusting

straightedge MP 1-312.
The adjusting straightedge should be centred as follows: Rotate the locked camshaft
until one end of the adjusting straightedge
makes contact with the cylinder head. Use a
feeler gauge to measure the clearance produced at the other end of the adjusting
straightedge. Insert a feeler gauge equal to
half the clearance measured, between adjusting straightedge and cylinder head. Now,
rotate the camshaft until the adjusting
straightedge touches the feeler gauge. Insert a second feeler gauge with the same
thickness at the other end between adjusting straightedge and cylinder head.
K-
Slacken the bolts -1- attaching the injection

pump sprocket.
Notes:
Use the locking pin 3359 for counterholding
the injection pump sprocket page 23-12,
Fig. A13-0052.
Always moisten the locking pin with oil. Use
a mirror to make it easier to insert the pin.
If it is not possible to lock the injection pump

sprocket with the locking pin, rotate the
crankshaft so that the holes for the locking
pin are aligned. Then, slacken the bolts of
the injection pump sprocket and, only now,
position the crankshaft to TDC.
On no account, slacken the central nut -2- of
the injection pump sprocket otherwise the
basic setting of the injection pump will be altered and can no longer be set with workshop tools.
------------
------------
Edition 03.98
S00.5111.52.20
OCTAVIA
23
Unscrew the nut of the tensioning pulley.
Take the toothed belt off the toothed belt

sprockets of the camshaft and injection
pump.
Unplug the connector for the electrical connections of the injection pump.
K-
Unscrew the securing bolts -1- at the mounting bracket.
Note:
On no account, slacken the central nut -2- of
the injection pump sprocket otherwise the basic setting of the injection pump will be altered
and can no longer be set with workshop tools.
K-
Then, unscrew the securing bolts from the

rear support -arrow-.
Take off the injection pump.
Installing
-
Insert the front securing bolts and tighten the

bolts to 25 Nm.
Loosely secure the injection pump sprocket

at the hub with new securing bolts (do not
rotate injection pump sprocket).
------------
Edition 03.98
S00.5111.52.20
Insert the injection pump into the mounting

bracket and first of all attach the bolt at the
rear support with the tapered nut.
------------
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Edition 12.00
S00.5111.54.20
The adjusting straightedge must not be used as

a counterholder when slackening and tightening the camshaft sprocket. Counterhold camshaft sprocket with special tool MP 1-216.
Note:
S
23
OCTAVIA
OCTAVIA
23
Note:
K Ensure the retaining claw is correctly positioned.
-
Tighten the securing nut to 20 Nm.
Once again, check the TDC marking at the

flywheel.
Tighten the new bolts for attaching the injection pump sprocket to 20 Nm.
Note:
The bolts for attaching the sprocket must only
be used once as these are stretch bolts.
-
Tighten the bolt for attaching the camshaft

sprocket to 45 Nm (counterhold with MP
1-216).
Remove the locking pin 3359.
Remove the adjusting straightedge MP 1-312

from the camshaft.
Rotate the crankshaft two revolutions in direction of rotation of engine until the crankshaft is again positioned at TDC of cylinder
1.
Check whether the injection pump sprocket

can be locked with locking pin 3359.
If it is not possible to lock the injection pump

sprocket:
-
Rotate the crankshaft sufficiently until the

holes for the locking pin are aligned and lock
the injection pump sprocket with locking pin
3359.
Slacken the bolts attaching the injection

pump sprocket.
Rotate crankshaft until the help marking on

the flywheel is aligned with the edge of the
adjusting device.
If it is possible to lock the injection pump

sprocket:
-
Edition 03.98
S00.5111.52.20
Tighten the bolts attaching the injection pump

sprocket to 20 Nm + turn (90).
Remove locking pin 3359.
------------
------------
23
OCTAVIA
Connect the injection lines, fuel feed line and

electric cables.
K-
Fill the injection pump with clean diesel fuel

as follows:
-
Screw the connection fitting V.A.G 1318/

10 into the return flow opening of the injection pump.
Connect the vacuum pump (e.g. V.A.G

1390) to the return-flow opening with a
transparent fuel line about 1 m long.
Operate the vacuum pump until fuel flows

out of the return-flow opening. Do not
draw fuel into the vacuum pump.
Install top toothed belt guard, vacuum pump

and cylinder head cover.
Install air guide pipe from intercooler with

hose to the intake manifold.
Install connectors at intake manifold pressure sender and intake manifold temperature sender.
Install right headlight Electrical System;

Repair Group 94; Exterior Lights/Bulbs/
Switches.
Install top engine trim panel.
Install sound-absorbing pan and air guide

pipe between intercooler and turbocharger.
Dynamically test and set commencement of

injection page 23-13.
------------
Close the return-flow pipe.
------------
Edition 03.98
S00.5111.52.20
6
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OCTAVIA
23
t
commencement
and
injection
Notes:
Commencement of injection must always be

checked and set, if necessary, after replacing the toothed belt or also after slackening
the bolted connections at the injection pump
or at the toothed belt sprockets.
Dynamic testing of commencement of injection is only possible in function 04 Basic
setting of engine as, during this function, the
commencement of injection valve is constantly actuated and the injection timing device is thus retarded.
t
and

V.A.G 1551/3, 3A, 3B or 3C
Torque wrench 5...50 Nm (e.g. V.A.G 1331)

Counterholder MP 1-216
Locking pin 3359
Initiate basic setting

1
2
3
4
0
9
10
Select function Basic setting, display group

001 page 01-21.
K-
Check readout in display block 7 (coolant

temperature).
Specification: less than 73 (equals 85 C)
Do not continue with the test until the coolant

temperature is reached.
Commencement of injection in display block

2 is dependent on the fuel temperature in
display block 9.
Specification: Figure - range C
A - Display block 2, commencement of injection

B - Display block 9, fuel temperature
C - Specified range for commencement of injection
Edition 12.00
S00.5111.54.20
------------
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------------
------------
Edition 12.00
S00.5111.54.20
13
Provided the check reveals that the commencement of injection is within the specified range
-C-, it is not necessary to carry out any new setting. After replacing the injection pump and the
engine control unit, the commencement of injection should be set to the mean value.
Note:
23
OCTAVIA
OCTAVIA
23
Slacken the third bolt attaching the injection

pump sprocket and turn the pump shaft
slightly:
Turning shaft to the left
commencement of injection retarded
Turning shaft to the right
commencement of injection advanced
Note:
On no account should you slacken the nuts -2for the hub otherwise the basic setting of the
injection pump will be altered and cannot be set
with workshop tools.
-
Tighten the new bolts for attaching the injection pump sprocket to 20 Nm + 1/4 turn (90)
(counterhold with locking pin 3359).
Note:
The bolts for attaching the sprocket must only
be used once as these are stretch bolts.
-
Install top toothed belt guard.
Install air guide pipe from intercooler with

hose to intake manifold.
Plug in connectors at intake manifold pressure sender and intake manifold temperature sender.
Install top engine trim panel.
Install right headlamp Electrical System;

Repair Group 94; Exterior Lights/Bulbs/
Switches.
Once again check commencement of injection for specified value.
If the commencement of injection is not within

the specified range:
Correct the setting at the injection pump
sprocket.
If the commencement of injection is not within

the specified range:
-
Check fuel injection control page 23-28,

replace injection pump if necessary.
Injection pump is o.k.:

-
Edition 03.98
S00.5111.52.20
Replace engine electronics control unit

page 23-20.
------------
------------
23
OCTAVIA
Removing and installing and testing injectors

Note:
Faulty injectors cause the following problems:
Loss of power
Excessive black smoke in exhaust
Intensified blue exhaust when starting from
cold
High fuel consumption
Engine overheats
Knocking in one or several cylinders
Misfiring
V.A.G 1551/3
Injector tester (e.g. V.A.G 1322)
Delivery pipe V.A.G 1322/2
Torque wrench 5...50 Nm (e.g. V.A.G 1331)
Ring wrench for injection pipes (e.g. 3035)
As need be, puller for valve stem seals MP
1-230 and auxiliary tool
Removing
-
Use the ring wrench (e.g. 3035) to detach

the injection pipes.
If necessary, unscrew banjo bolt for returnflow pipe (injector of cyl. 3).
Note:
Always remove all of the injection pipes. Do not
alter the shape.
-
Shop-make the following auxiliary tool for

injectors which are tight:
------------
Unscrew securing bolt, take off tensioning

clamp and remove injector.
------------
Edition 05.97
S00.5111.51.20
OCTAVIA
23
Preparing an auxiliary tool
-
Saw off an injection line (e.g. spare part line)

approx. 5 cm behind the nozzle union nut.
Hard solder an M6 bolt to the sawn off line.
Thoroughly clean the auxiliary tool, the injection nozzle cannot be used if dirty!
K-
Tighten the union nut of the auxiliary tool on

the jammed nozzle and insert the extractor
MP 1-230 on the welded nut.
Note:
Store the auxiliary tool with dust protection for
future use.
Installing
Note:
Always replace the copper seal and O-ring between the cylinder head and injection nozzles.
-
Insert injection nozzles.
Pay attention to correct fitting of the bracket

in the cylinder head.
Insert clamp and tighten fixing screw.
Tightening torques:
Injection lines: 25 Nm
Banjo bolt for return line (cyl. 3): 10 Nm
Screw for clamp: 20 Nm
Testing
-

13
0.82 mg/H -0.12 mg/H 0.49 mg/H

and activate the function Reading measured
value block page 01-28.2.
K-
Reading measured value block, display group

013, engine in idle page 01-47.
Specified value: -1.50 mg/H...+1.50 mg/H
(milligram per stroke)
Edition 09.03
S00.5111.55.20
If one or several specified values are outside the tolerance, interchange the injection
nozzles (except for the nozzle of cylinder 3).
------------ 23-17 ------------
23
OCTAVIA
If the fault moves with the injector, replace

the relevant injector.
If the fault remains at the cylinder, test the

compression.
If the compression is o.k., replace the relevant delivery valve together with seal
page 23-4, Servicing injection pump.
Notes:
Always use a soft object (plastic, wood) to
remove the seal from the pump otherwise
the sealing surface may be scratched.
If the car has covered more than 15000 km,
always replace the set of delivery valves.
This engine is equipped with 2-spring injectors.
The quantity of fuel is injected in this case in 2
stages.
If there is any problem with these injectors, it is
only possible to replace them as it is neither
possible to set the pressure nor to repair the
injector.
K Test injectors with injector tester (e.g. V.A.G

1322) and pressure pipe V.A.G 1322/2.
Important!
When testing injectors, ensure that the fuel spray
does not strike your hands otherwise the fuel will
penetrate into the skin as a result of the high pressure and may cause severe injuries.
l Pressure gauge switched on
-
Slowly press the pump lever down. When

fuel ejection starts, read off the ejection pressure. If the ejection pressure differs from the
specified pressure, replace the injector.
New injectors
Wear limit
19...20 MPa
17 MPa
Testing for leaks

l Pressure gauge switched on
-
------------
------------
Slowly press the pump lever down and maintain the pressure at about 15 MPa for 10
seconds. During this time, no fuel should drip
out of the injector opening.
If a leak exists, replace injector.
Edition 05.97
S00.5111.51.20
OCTAV1A
23
Wiring and Component Test with

Test Box
Note:
For testing use e.g. the handheld multimeter

-V.A.G 1526 A or B-, also the voltage tester
e.g. -V.A.G 1527 B-.
For connecting measuring equipment (e.g.
voltage tester, handheld multimeter etc.) always use the adapter cable set e.g. -V.A.G
1594 A, B or C-
The contact numbers of the connector of the

control unit and the socket numbers of the
test box are identical.
Attention!
To avoid damaging the electronic components,

switch on the relevant measuring range before connecting the measuring cables and comply with the
test conditions.
Test box -V.A.G 1598/22- or -V.A.G 1598/31Test procedure
-
Switch off ignition.
Unscrew windscreen wiper arms and remove

cover of plenum chamber
Body Work, Repair Group 66.
-
Release the plug locks and unplug the plug

connector of the engine control unit.
For the test box -V.A.G 1598/22K-
Edition 01.04
S00.5111.56.20
Connect test box -V.A.G 1598/22- to connector of wiring loom.

Perform test as described in the relevant repair sequences.
------------ 23-19 ------------
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Edition 12.00
S00.5111.54.20
Notes:
23
OCTAVIA
Edition 12.00
S00.5111.54.20
23
------------
OCTAVIA
------------
23
OCTAV1A
Replacing engine control unit

Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3C-
038906018.. 1.9 l R4 EDC G00SG 1002
Coding 00002
WSC 01234
Connect vehicle system tester -V.A.G 1552and select engine electronics control unit
page 01-2.
K The control unit identification appears in the display, e.g.:

-
Part no. of control unit part and write in coding.
End output (function 06).
Removing
-
Switch off ignition.
Unscrew windscreen wiper arms and remove

cover of plenum chamber
Body Work, Repair Group 66.
-
Release the plug locks and remove the control unit plugs.
K-
Use a screwdriver to push the catch of the

fixture to the side and pull the engine control
unit forward.
Installing
The installation occurs in reverse order.
-
Check current coding and code new control

unit page 01-23.
Adjust the engine control unit to the immobilizer control unit

Electrical System Repair Group 96.
-
On vehicles fitted with CCS; activate CCS

page 23-54.
Interrogate the fault memory, erase the fault

memory, if necessary eliminate any faults
which exist page 01-5.
For vehicles 08.03

-
------------ 23-20 ------------
Generate readiness code page 01-26.
Edition 01.04
S00.5111.56.20
Edition 12.00
S00.5111.54.20
23
------------
OCTAVIA
------------
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------------ 23-22 ------------
Edition 12.00
S00.5111.54.20
11
01
Have a second person operate V.A.G 1552.

Warning!
and
tem
23
OCTAVIA
OCTAVIA
23

If the charge pressure measured is too low, the
following faults are possible:
Hose of charge pressure control dropped off,
leaking or blocked.
Charge pressure control solenoid valve (N75)
blocked.
Mechanism (linkage, shaft) of bypass valve
stiff or jammed (bypass valve constantly open).
Pressure unit leaking.
If the charge pressure measured is o.k., repeat
measurement of charge pressure with charge
pressure control:
-
Plug in connector at charge pressure control solenoid valve (N75).
Read measured value block, display group

011, engine idling page 01-58.
Accelerate vehicle in 3rd gear at full throttle

for about 1500 rpm.
At about 3000 rpm check readout in display

block 3 and note.
Models 07.97
3090 rpm
1866 mbar 1917 mbar
11
62 %
Specification in display block 3:

1800...2050 mbar
Models 08.97 04.99

3090 rpm
1866 mbar 1917 mbar
11
62 %

1700...2080 mbar
Models 05.99

3090 rpm
1866 mbar 1917 mbar
11
62 %

1850...2250 mbar
Continued for all models
If the charge pressure measured is too low, the
following faults are possible:
Electrical fault in charge pressure control

solenoid valve.
Charge pressure control solenoid valve

(N75) jamming in open position.
If the charge pressure measured is too high,

the following faults are possible:
Charge pressure control solenoid valve (N75)
occasionally jamming in closed position.
Charge pressure increase as a result of tuning.

Edition 12.00
S00.5111.54.20
------------
------------
23
OCTAVIA
Testing charge pressure control solenoid valve (N75)

Hand-held multimeter (e.g. V.A.G 1526 A)
Adapter cable set (e.g. V.A.G 1594 A)
Test box V.A.G 1598/22 or V.A.G 1598/31
V.A.G 1551/3, 3A, 3B or 3C
Diode test lamp (e.g. V.A.G 1527 B)
Test condition
l Fuses 29 and 34 o.k.
Test procedure
-

page 01-2.
Select final control diagnosis and activate

charge pressure control solenoid valve -N75
page 01-18.
If the valve is not actuated (does not click):

K-
Unplug connector -1- from charge pressure

control solenoid valve (N75) and connect
diode test lamp between contacts of connector.
Diode test lamp must flash.

Diode test lamp flashes.
End final control diagnosis.
Switch ignition off.
Connect multimeter to valve -2- for resistance measurement.
Models 07.00
Specification: 25...45
Models 08.00
Specification: 14...20
If the specification is not achieved:
------------
------------
Edition 12.00
S00.5111.54.20
OCTAVIA
23

-
Replace charge pressure control solenoid

valve (N75).
Diode test lamp does not flash:

-
End final control diagnosis.
Connect multimeter for voltage measurement

to contact 1 of connector -1- and to earth.
Switch ignition on.

!

Specification: approx. battery voltage

-
Connect test box to wiring loom to engine

control unit page 23-19.
est
K Test the following cable connections for short

circuit to positive and to negative and also for
open circuit (connector -1-).
2-pin connector at wiring
loom, contact
est
2, 28
.
socket
15
Rectify any open circuit or short circuit in the

wiring.
est

circuit to positive and to negative and for open
circuit (connector -1-).
2-pin connector at
wiring loom, contact
1
2
est
.
socket
1, 2
62

wiring.
If no fault is found in the wiring:

-
Edition 12.00
S00.5111.54.20
Replace engine control unit (J248) page

23-20.
------------
------------
23
------------
------------
OCTAVIA
Edition 12.00
S00.5111.54.20
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OCTAVIA
23
ture sender
t
testers and aids

V.A.G 1551/3, 3A, 3B or 3C

15.4 C
16.7 C
K-

007; engine switched off and cooled down
page 01-51.
Observe readout in display block 3.
Note:
If an open circuit exists in the wiring to the sender,

a substitute value of 136.8 C is displayed.
-
End output (function 06) and switch ignition

off.
If an implausible temperature, or a substitute

temperature of 136.8 C is displayed:
K-
Edition 12.00
S00.5111.54.20
Unplug connector -1- from the intake manifold temperature sender -2-.
Connect multimeter for resistance measurement to contacts 1 and 2 of the intake manifold temperature sender -2-.
------------
------------

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Test
Edition 12.00
S00.5111.54.20
52
Test
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Test
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23
OCTAVIA
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------------
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Edition 12.00
S00.5111.54.20
1013
10
testers and aids
Testing
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23
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------------
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OCTAVIA
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23
control
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2
3
connection at
control
unit
acuum
element
valve
3
4
return valve
white connection points toward charge
pressure control solenoid valve -N75
acuum unit
o air
control
unit
for charge pressure control valve
part of turbocharger, cannot be replaced separately
10
11
valve
recirculation
acuum
12
13
Edition 12.00
S00.5111.54.20
return valve
------------
------------
23
OCTAVIA
Testing start of injection control

Testing injection timing control
range
V.A.G 1551/3
Procedure
Start of injection valve -N108
Initiate final control diagnosis and actuate the

start of injection valve page 01-18.
Actuation of the valve is indicated by a clearly
audible change in the combustion noise (diesel combustion noise).
-
Basic setting
42 46 0 20
90
201
64
153
0
127
Initiate the basic setting page 01-21.
K Readout in display, e.g.:
83
-
K-
Set start of injection, if necessary

page 23-13.
Remove the fuse 34 -arrow-.
Basic setting
42 255 0 20
90
201
64
153
0
127
83
Observe the readout in display zone 2.

The readout should increase to 255
Note:
As a result of the interruption to the voltage, the

start of injection valve is closed. The pump internal chamber pressure can no longer be lowered and acts to its full extent on the piston of
the injection control. The injection control is
moved toward the advanced stop.
------------
------------
Edition 05.97
S00.5111.51.20

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S00.5111.54.20
------------
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testers and aids
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OCTAVIA
Edition 12.00
S00.5111.54.20
23
------------
OCTAVIA
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Edition 12.00
S00.5111.54.20
1.
Test procedure
testers and aids
Testing
23
temperature sender
OCTAVIA
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OCTAVIA
Specification:
Specification in field A applies to temperature

0...50 C, in field B to a temperature of 50...100
C.
Example:
A temperature of 30 C equals a specification of 1500...2000

A temperature of 80 C equals a specification of 275...375
Replace injection pump
page 23-8.
If the specification is achieved:

-
Connect test box to wiring loom to engine

control unit page 23-19.
est

10-pin connector at
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socket
53

wiring.
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4
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Edition 12.00
S00.5111.54.20
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wiring.
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Edition 12.00
S00.5111.54.20
23
OCTAVIA
Edition 12.00
S00.5111.54.20
23
------------
OCTAVIA
------------
23
OCTAVIA
Testing exhaust gas

Testing exhaust gas recirculation
Operation of the exhaust gas recirculation system is tested by measuring the inducted air
mass. If exhaust gas is recirculated, the fresh
air portion which is detected by the air mass
meter is less. The greater the quantity of exhaust gas recirculated, the smaller the signal
supplied by the air mass meter.

V.A.G 1551/3
Procedure for models 07.97
900 rpm
6.5 mg/H
1.480 V
87.3 C

-
Check readout in display block 4 (coolant

temperature).
Specification: at least 85 C
Do not continue with the test until the coolant

temperature is reached.
-

900 rpm
272 mg/H
3
268 mg/H
54 %
Press the key C.
Press the key 0 twice and key 3 for Display

group number 003 and confirm the entry with
the key Q.
-

900 rpm
272 mg/H
3
268 mg/H
54 %
Briefly blip the throttle and then allow the

engine to continue idling.
K-
Check the readout in display block 2 (specified air mass).

Specification: 230...370 mg/H
If the air mass is higher than specified, the cause

may be the following:
Coolant temperature too low
Intake manifold temperature very high

Injected quantity too high
------------ 23-32 ------------
Edition 03.98
S00.5111.52.20
OCTAVIA
23
Fault in fault memory

900 rpm
272 mg/H
3
268 mg/H
54 %
K-
Check the readout in display block 3 (actual

air mass).
Specification: should agree with specified air
mass in display block 2
(tolerance 20 mg/H)
If the actual air mass is more than 20 mg/H lower

than the specified air mass, the following faults
are possible:
Unmetered air in intake area
Excessive exhaust gas recirculation
If the actual air mass is more than 20 mg/H
higher than the specified air mass, the following faults are possible:
Engine has been idling for 3 minutes
Insufficient or no exhaust gas recirculation
If the actual air mass is a constant 425 mg/H,

the following faults are possible:
Open circuit in wiring to air mass meter
Implausible air mass detected
If the specifications are not achieved:

-

EGR valve -N18
Start final control diagnosis and operate the

EGR valve page 01-18.
The valve should click.
If the valve does not click:

-
Test EGR valve (N18)
page 23-34.
If the valve clicks:

-
Check the vacuum hoses
page 23-37.
If the vacuum hoses are o.k.:

-
Edition 03.98
S00.5111.52.20
Test mechanical exhaust gas recirculation

valve:
1.9-ltr./66 kW Engine, Mechanical Components; Repair Group 26; Exhaust gas
------------ 23-33 ------------

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------------
------------
Edition 12.00
S00.5111.54.20
If a constant value of 550 mg/H is shown in display block 3, test the air mass meter page
23-35.
Note:
4
4
23
OCTAVIA
Edition 12.00
S00.5111.54.20
23
------------
OCTAVIA
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OCTAVIA
Testing electromagnetic
gas recirculation
testers and aids


Test condition
29 and 34
l
T
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onnect
tester and select
engine electronics control unit page 01-2.
control diagnosis and

Select
exhaust gas recirculation solenoid
page 01-18.
the
is not actuated (does not
K-
connector -1- to the exhaust gas

recirculation solenoid
onnect multimeter
resistance measurement to the
-2-.
14...20
the
exhaust gas recirculation solenoid
the
ignition on.
the
------------
------------
is
onnect multimeter
measurement to contact 1 o connector -1- and to
earth.
is not
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loom to the
engine control unit page 23-19.
Edition 12.00
S00.5111.54.20
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23

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61

wiring.

-
Edition 12.00
S00.5111.54.20

23-20.
------------
------------
23
------------
------------
OCTAVIA
Edition 12.00
S00.5111.54.20
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23
air mass meter
The signal from the air mass meter is required

by the control unit for calculating the permissible injected quantity and for controlling the exhaust gas recirculation. The smaller the signal
supplied by the air mass meter, the less fuel
may be injected.
t
testers and aids

V.A.G 1551/3, 3A, 3B or 3C

est condition

Warning!

mg/H
1030 mbar
1011 mbar
10
0.0 %
K-
Observe readout in display block 1.

Specification: 230...370 mg/H

-
Test exhaust gas recirculation page 23-32.

-

830 mg/H
1030 mbar 1850 mbar
Edition 12.00
S00.5111.54.20
10
100 %
Accelerate vehicle in 3rd gear at full throttle

from about 1500 rpm.
At about 3000 rpm, check readout in display

block 4 and note.

100 % (accelerator pedal position)
------------
------------
23
Fuel Formation/ Fuel Injection
OCTAVIA

-
Repeat the test and accelerate the vehicle

at full throttle.
Models 07.97

830 mg/H
1030 mbar 1850 mbar
10
100 %

1800...2050 mbar (charge pressure)

830 mg/H
1030 mbar 1850 mbar
10
100 %

>750 mg/H (inducted air mass)
Models 08.97

830 mg/H
1030 mbar 1850 mbar
10
100 %

1700...2080 mbar (charge pressure)

830 mg/H
1030 mbar 1850 mbar
10
100 %

>800 mg/H (inducted air mass)

-
Test charge pressure page 23-22.
Replace the air mass meter (G70).
If a constant readout appears in display block 1

(fixed substitute value):
Models 07.97 = 425 mg/H
Models 08.97 = 550 mg/H
------------ 23-36 ------------
Edition 02.99
S00.5111.53.20
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S00.5111.54.20
Test
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S00.5111.54.20
------------
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Test the following cable connections for short

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Edition 12.00
S00.5111.54.20
diesel direct
base
position
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S00.5111.54.20
------------
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23
OCTAVIA
Testing brake light switch and

brake pedal switch
In view of the fact that the fuel injection system
operates with an accelerator pedal sender
(potentiometer), which could develop a fault, the
engine is governed for safety reasons when the
brakes are applied. The control unit requires the
brake light switch signal and, in addition, the
brake pedal switch signal for this purpose. What
this means, therefore, is that, if the brake is operated when the accelerator pedal is constantly
depressed, the engine is immediately governed
down to idling speed. If the switch positions are
not clearly detected, this can result in unintentional governing of the engine speed.

V.A.G 1551/3
Procedure
0 km/h
000
6
000000
-

0 km/h
000
6
000000
6
000000
Check readout in display block 2.

Specification: 0 0 0

0 km/h
011

Slowly depress brake.
Both readouts should jump from 0 to 1.
Middle readout = brake pedal switch
Right-hand readout = brake light switch

0 km/h
000
6
000000
Slowly release brake pedal into rest position.

Both readouts should switch back again from
1 to 0.
If one of the readouts or both does not switch

from 0 to 1:
-
------------ 23-44 ------------
Test the switches or the cable connections

to the switches.
Edition 03.98
S00.5111.52.20
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S00.5111.54.20
------------
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100.0
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23
OCTAVIA
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S00.5111.54.20
0
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23
OCTAVIA
OCTAVIA
23

Test the wiring between test box and connector
of sender for open circuit according to the current flow diagram:
6-pin connector at
Test box V.A.G 1598/22,

socket
11
24
23
12
6
-
25

wiring.

-

23-20.
Models 08.98
- Remove bottom part of dash panel

Body Fitting Work; Repair Group 68.
-
Unplug 6-pin connector for accelerator pedal

position sender (G79).
K-
Test resistance of accelerator pedal position

sender:
Accelerator
Contacts
not depressed
2+3
not depressed
not depressed
depressed
depressed
not depressed
4+3
5+6
1+6

-
Edition 12.00
S00.5111.54.20
Specification
0.6...1.4 k
0.6...1.4 k
0.6...1.4 k
0.6...1.4 k
Replace accelerator pedal position sender

(G79).
------------ 23-48.1 ------------
23
OCTAVIA

K-
Test voltage supply of accelerator pedal position sender:

6-pin connector at
Specification
2+3
approx. 5 V
2 + earth
approx. 5 V
1 + earth
approx. 5 V
1+6
approx. 5 V

-
Connect test box to the wiring loom to the


K Test the wiring between test box and connector
6-pin connector at
Test box V.A.G 1598/22,

socket
11
23
12
4
6
-
------------ 23-48.2 ------------
24
25

wiring.
Edition 12.00
S00.5111.54.20
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K Test the wiring between test box and connector

open circuit or short circuit in the
no fault is found in the wiring:
Edition 12.00
S00.5111.54.20
engine control unit
page
------------ 23-48.3 ------------
23
------------ 23-48.4 ------------
OCTAVIA
Edition 12.00
S00.5111.54.20
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OCTAVIA
23
additional
and to air
The AC compressor is switched off by the engine control unit in the following situations:
when accelerating from a low speed (recognised by change in angle and accelerator
pedal position sender and from the vehicle
speed signal)
in the emergency programme (emergency
mode)
if the coolant is hotter than 120 C
for about 6 seconds each time the engine is

started
l Air conditioning o.k.
l Air conditioning switched on

l No fault in fault memory
t
and

V.A.G 1551/3, 3A, 3B or 3C

Hand lamp

AC compressor control
K-
Initiate final control diagnosis and actuate AC

compressor control page 01-18.
AC compressor must stop within 5 seconds

(visual check with hand lamp), and then run for
5seconds and stop again.
If the AC compressor does not switch off:
Edition 12.00
S00.5111.54.20
------------
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Edition 12.00
S00.5111.54.20
contact
16
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23
OCTAVIA

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23
111
2
18.4 C
Specification in display block 3: X X 1 (AC

signal)

-

.
Test the wiring for short circuit to positive and to

negative and also for open circuit.
.
48
contact

Electrical Fault Finding,
Fitting Locations binder

wiring.
.
Test the wiring for short circuit to positive and to

negative and also for open circuit.
.
49
Edition 12.00
S00.5111.54.20
contact

Electrical Fault Finding,
Fitting Locations binder

wiring.
------------
------------
23
------------
------------
OCTAVIA
Edition 12.00
S00.5111.54.20
@
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OCTAVIA
23
This signal is used to avoid overrevving and load

change jolts when the clutch is released, and is
required for the cruise control system.
t
and

V.A.G 1551/3, 3A, 3B or 3C

condition
l Fuses o.k.

0 km/h
000
000000

0 km/h
100
000000

006; engine switched off page 01-35.
Specification in display block 2: 0 X X
Depress clutch.
Specification: 1 X X

-
End output (function 06) and switch the ignition off.
Unplug the connector of the clutch pedal

switch page 23-2, Overview of fitting locations.
K-
Connect the multimeter for resistance measurement between the contacts of the switch.
Specification:
Clutch not depressed: max. 10
Clutch depressed:

-
Replace clutch pedal switch (F36).
Edition 12.00
S00.5111.54.20
------------
------------
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Edition 12.00
S00.5111.54.20
at
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23
OCTAVIA
Edition 12.00
S00.5111.54.20
23
------------
OCTAVIA
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Edition 12.00
S00.5111.54.20
000
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Warning!
and
condition
23
OCTAVIA
23
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-
Diode test lamp must flash (about 4x for each

revolution of wheel).
Note:
Ensure that the right front wheel does not rotate.

If the diode test lamp does not flash:

open circuit.
.
51
contact

wiring.
.
Connect diode test lamp between socket 1

(earth) and socket 20 (vehicle speed signal).
Switch ignition on and rotate front left wheel

by hand.
Diode test lamp must flash (about 4x for each

revolution of wheel).
Note:
Ensure that the right front wheel does not rotate.

If the diode test lamp does not flash:

open circuit.
.
20
contact

wiring.

-
Edition 12.00
S00.5111.54.20
Determine all the users of the vehicle speed

signal (e.g. radio, air conditioning, etc.), separate the connection to the dash panel insert
one after the other and repeat the test until
the cause is determined.
------------
------------
23
------------
------------
OCTAVIA
Edition 12.00
S00.5111.54.20
E
F
D
D
C
3

1

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OCTAVIA
23
and

V.A.G 1551/3, 3A, 3B or 3C
The engine speed signal is required for the rev

counter and for the air conditioning. If an automatic gearbox is fitted, it is also required for
calculating the shift points.
The signal shape which is generated by the
engine speed sender (G28), cannot be analysed
however and it is therefore first of all processed
in the engine control unit.
The engine speed is determined as follows:

rpm
5.6 mg/H
1.480 V
1
87.3 C

001; engine idling page 01-38.
Briefly operate full throttle.

The current engine speed must be displayed
(evenly over entire range). This engine speed
display must agree with the revs indicated
on the right counter.

-

.
Test cable connection from rev counter to

contact 6 of test box for open circuit
Finding, Fitting Locations binder.
.
Test cable connection from rev counter to

contact 27 of test box for open circuit
Finding, Fitting Locations binder.
Edition 12.00
S00.5111.54.20
------------
------------
6
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Edition 12.00
S00.5111.54.20
1552
condition
and
control
23
01
OCTAVIA
OCTAVIA
23
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038906012F 1.9l
Coding 00001
R4 EDC G000AG 2813

WSC 01234
K If G000AG is displayed, cruise control system

is activated.
038906012F 1.9l
Coding 00001
R4 EDC 0000AG 2813

WSC 01234
K If 000AG is displayed, cruise control system is

deactivated.

Select function XX
HELP
-
Enter 11 for the function Login procedure

and confirm entry with the key Q.
Enter code number as specified in the table

below and confirm entry with the key Q.
Activate CCS
11463
Deactivate CCS
16167
End output (function 06).
Conduct a road test.
cruise control
With the exception of an operating switch, the

CCS does not have any separate components.
All the functions are performed by the engine
control unit. The minimum vehicle speed for the
cruise control function is 30 km/h.
t
testers and aids

V.A.G 1551/3, 3A, 3B or 3C
Test condition
l Fuses o.k.
T
-
Edition 12.00
S00.5111.54.20

006; engine idling page 01-35.
------------
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S00.5111.54.20
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------------
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Edition 12.00
S00.5111.54.20
------------
23
OCTAVIA
Servicing intake manifold flap 08.97
1 - Intake manifold
2 - 10 Nm
3 - O-ring
Replace
4 - Intake connection
With exhaust gas recirculation valve
and intake manifold flap
5 - 10 Nm
6 - Gasket
Replace
7 - Connection pipe
To exhaust manifold
8 - 25 Nm
9 - Vacuum positioning element for intake
manifold flap
-N239
Testing page 23-57
The intake manifold flap is closed for about 3
seconds when the engine is switched off and
then opens again. This reduces the engine stop
jolt.
11 - Vacuum supply
From vacuum pump
Testing intake manifold flap changeover page

23-57.
------------ 23-56 ------------
Edition 03.98
S00.5111.52.20
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and
Hand vacuum pump (e.g. V.A.G 1390)

Current flow diagram
condition
Start engine and run at idling speed for about

5 seconds.
Observe positioning lever at intake manifold

flap (2nd person required).
After the ignition is switched off, the intake

manifold flap must close for about 3 seconds,
then move back into its original position.
If the intake manifold flap does not switch over,

perform the following inspections:
-
Inspect switchover mechanism of intake

manifold flap by operating the linkage by
hand. It must be possible to easily move the
intake manifold flap.
Ensure the vacuum hoses are correctly attached and connected as specified in the
hose diagram page 23-59.
Detach vacuum hose at vacuum positioning

element for intake manifold flap.
Connect hand vacuum pump to vacuum positioning element.
Operate hand vacuum pump.
Intake manifold flap must close.
Edition 12.00
S00.5111.54.20
------------
------------

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S00.5111.54.20
------------
------------
13
12
11 Vacuum
10
recirculation
Pressure unit
control solenoid
o air
Vacuum unit

3
2
1 Vacuum
element
models 08.97
models 08.97
Vacuum
element
Vacuum
o
o air
recirculation
OCTAVIA
23
OCTAVIA
28
Glow Plug System
Testing glow plug system

Testing operation
Hand-held multimeter (e.g. V.A.G 1526)
Current flow diagram
Test conditions
l Diesel direct injection system control unit
(J248) o.k.
l Strip fuse for glow plugs (S 132) o.k.
Test procedure
K-

Unplug connector -1- at the coolant temperature sender (G62) -2-.
Note:
When the connector is unplugged from the
sender, the cold engine state is simulated and
appropriate glow plug heating operation is carried out when the ignition is switched on.
-
Unplug the glow plug connectors from the

glow plugs.
Connect the multimeter for voltage measurement to a glow plug connector and to engine
earth.
Switch on the ignition.

approx. battery voltage
should be displayed for about 20 seconds.
If no voltage is present:
-
Rectify any open circuit in the wiring or short

circuit.
During the simulated glow plug heating operation, the glow period warning lamp (K29) should
come on.
Edition 03.98
S00.5111.52.20
------------ 28-1 ------------
28
OCTAVIA
Glow Plug System

If the warning light does not come on:
-
Test glow period warning light page 28-2.
Testing glow plugs

Diode test lamp (e.g. V.A.G 1527 B)
Hinged wrench for glow plugs (e.g. 3220)
Test condition
Test procedure
-
Unplug glow plug connectors from the glow

plugs.
Connect cable of diode test lamp to battery

positive (+).
Switch ignition on.
K-
Connect test prod of diode test lamp to each

glow plug one after the other.
LED comes on: glow plug o.k.
LED does not come on: replace glow plug.
Use hinged wrench, e.g. 3220, for removing

and installing the glow plugs.
Tightening torque: 15 Nm
Testing glow period warning light

V.A.G 1551/3, 3A, 3B or 3C
Test condition
l Fuse 29 o.k.
------------ 28-2 ------------
Edition 12.00
S00.5111.54.20
OCTAVIA
Glow Plug System

-

Glow period warning light -K29
28
Initiate final control diagnosis and operate

glow period warning light page 01-18.
The warning light must flash.
If the warning light does not flash:

-


-
Use an adapter cable to connect sockets 1

and 41 of the test box.

-
Use an adapter cable to connect sockets 1

and 42 of the test box.

-
Switch ignition on.

Warning light must come on.
If the warning light does not come on:

-

wiring
Current Flow Diagrams, Fault Finding,
Fitting Locations binder.
If the warning light now comes on, but not during
final control diagnosis:
-
Edition 12.00
S00.5111.54.20

23-20.
------------ 28-3 ------------

Manual Service Workshop Manual Octavia Engine Fuel Injection 1.9tdi 01-23-28

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Service

Service Department. Technical Information

Printed in Czech Republic

Basic Edition of Workshop Manual

Supplement to Basic Edition

Contents next page.

The Service Manual is intended only for use within the

Actuator diagnosis ......................................................................................................................

Measured value blocks ...............................................................................................................

Readiness code ...........................................................................................................................

Servicing a diesel direct fuel injection system .........................................................................

Testing injection control .............................................................................................................

Inspecting exhaust gas recirculation system ...........................................................................

Inspecting control units input quantities ..................................................................................

Servicing intake manifold 08.97 ............................................................................................

Testing auxiliary signals .............................................................................................................

Glow plug system

Inspecting glow plug system .....................................................................................................

Technical data of self-diagnosis

------------ 01-5 -----------01-1

Functions available when using vehicle system tester V.A.G 1552

01 Interrogate control unit

02 Interrogate fault memory

05 Erase fault memory

07 Code control unit

08 Read measured value

Only perform when ignition switched on if

Connecting vehicle system tester

l Earth connections at gearbox and on left

------------ 01-2 ------------

Connect vehicle system tester V.A.G 1552

After the vehicle system tester has been connected:

Depending on the desired function, switch

If the readouts which appear in the display do

Test of vehicle systems

Test of vehicle systems

Test of vehicle systems

Test of vehicle systems

Test of vehicle systems

If Error in data transmission is displayed

K If one of the following messages appears in

Operate the vehicle system tester on the basis

038906018BQ 1.9 l R4 EDC G00SG 2112

K The control unit identification appears in the display, e.g.:

Engine displacement version (4 cyl. in-line engine)

Vehicle with or without

Control unit mapping

Data status (software version) of control unit

Coding 00002 Coding variant of control unit

Workshop code from the

List of all control units

For current control unit version - spare parts

------------ 01-4 -------------

Reduction in life of automatic gearbox

Check coding of engine control unit page

For further procedure Repair descriptions.

Interrogating and erasing fault

Connect vehicle system tester V.A.G 1552

Only if the engine does not start:

Switch ignition on.

Enter 02 for the function Interrogate fault

K The number of stored faults or No fault recognized! appears in the display.

Enter 06 for the function End output and

------------ 01-9 -----------01-5