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OCTAVIA 1997
OCTAVIA 1997
1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System
Edition 03.01
Supplement 1 2
Subject Basic Edition Modifications in Rep. Gr. 01 and 23 Modifications in Rep. Gr. 01 23 and 28
List of Supplements
OCTAVIA 1997
List of Supplements
OCTAVIA 1997
Table of Contents
01 Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 - Properties of the self-diagnosis ..................................................................... 01-1 - Technical data of self-diagnosis ..................................................................... 01-1 - Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics .............................................................................................. 01-1 - Interrogating and erasing fault memory ............................................................ 01-1 - Actuator diagnosis ..................................................................................... 01-1 Self-diagnosis II ......................................................................................... 01-2 - Fault table .............................................................................................. 01-2 Self-diagnosis III ........................................................................................ 01-3 - Readiness code ........................................................................................ 01-3 - Reading readiness code .............................................................................. 01-3 - Generating readiness code .......................................................................... 01-3 Self-diagnosis IV ....................................................................................... 01-4 - Reading measured value block ..................................................................... 01-4 - Display groups 001 to 022, engine idling .......................................................... 01-4 - ........................................................ Display groups 004 through 011 at full load 01-4 - Display group 125 - CAN databus .................................................................. 01-4 page page page page page page page page page page page page page page page 1 1 1 2 3 5 1 1 1 1 1 2 1 1 1
page 10 page 12
Table of Contents
OCTAVIA 1997
1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System page page page 1 1 2
Testing preheating system ........................................................................... 28-1 - Check for proper operation .......................................................................... 28-1 - Checking glow plugs .................................................................................. 28-1
II
Table of Contents
OCTAVIA 1997
01
01 Self-diagnosis
01-1 Self-diagnosis I
Available functions when using the vehicle system tester -V.A.G 1552The preconditions for selecting the desired functions are given in the following table.
Self-diagnosis I
01-1 page 1
01
OCTAVIA 1997
Condition Operation 01 02 03 04 05 06 07 08 11
1)
Engine not running, ignition switched on yes yes1) yes no yes yes yes yes yes
Interrogating control unit version Interrogating fault memory Actuator diagnosis Basic setting Erasing fault memory Ending output Coding control unit Reading measured value block Login procedure
Only perform with the ignition on, if the engine does not start.
Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics
Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Battery voltage at least 11.5 volts Earth connection to engine and gearbox O.K. Fuses must be OK in compliance with the current flow
diagram.
Procedure
1 4
2 5 7
3 6 8 C O 9 Q
HELP
V.A.G.1552
Connect vehicle system tester - V.A.G 1552- with cable. Once the vehicle system tester has been connected:
Switch on ignition or start 01-1 page 1 engine depending on the function desired. Note If data transfer errors are displayed as a result of an incorrect entry, disconnect cable at vehicle system tester, connect it in again and repeat all the steps. If one of the following messages appears in the display, test the diagnostic cable Current Flow Diagrams, Electrical Fault Finding and Fitting Locations or Operating Instructions of vehicle system tester.
Vehicle system test The control unit does not respond
S01-0045
HELP
01-1 page 2
Self-diagnosis I
OCTAVIA 1997
01
HELP
Vehicle system test Fault in communication set-up Vehicle system test K cable does not connect to earth
HELP
Vehicle system test HELP K cable does not connect to pos. term.
HELP
The control unit identification appears in the display, e.g.: 038906019R = Part No. of control unit (for current control unit version refer to Parts List) 1.9 ltr. = engine displacement R4 = engine version (4 cyl. in-line engine) EDC = Injection system (Electronic Diesel Control) CC = Cruise control system activated (only on models with CCS) 000 = Control unit ID MG = Manual gearbox 1053 = Data status (Software version of the control unit) Coding 00003 = Coding version of control unit WSC XXXXX = Workshop identification Note If the control unit version displayed does not correspond to the vehicle, replace the control unit Chapter 23-5. Incorrect coding of the engine control unit results in: Handling problems (jerky gear change, load change jolts etc.) Increase in fuel consumption Increase in pollution Storage of non-existent faults in fault memory
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics 01-1 page 2.
Self-diagnosis I
01-1 page 3
01
OCTAVIA 1997
Switch on ignition. Enter function 02 Interrogate fault memory and confirm entry with the Q key. The number of stored faults or No fault recognised appears in the display. If no fault is stored:
X faults detected!
Press
Press
Press
Rectify the faults displayed by referring to the fault table Chapter 01-2. Note When carrying out testing and removal and installation operations faults such as connector unplugged or CAN bus faults, 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:
The Vehicle system tester -V.A.G 1552- sends all the known address words one after the other.
01-1 page 4
Self-diagnosis I
OCTAVIA 1997
01
Note If the ignition is switched off during Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Actuator diagnosis
With the actuator diagnosis the following parts are activated in the sequence indicated: 1 - Exhaust gas recirculation valve -N182 - AC compressor engagement 3 - Solenoid valve for charge pressure control -N754 - Changeover valve for intake manifold flap -N2395 - Glow period warning lamp -K296 - Radiator fan control 7 - Glow plug relay -J528 - Low heat output relay -J3599 - High heat output relay -J36010 - Fault lamp Note Actuation of the individual control elements is limited to 30 seconds. If final control diagnosis is to be repeated wirthout starting the engine in-between, switch ignition off for about 20 seconds. Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics 01-1 page 2.
Self-diagnosis I
01-1 page 5
01
Readout on display: The valve must click. Note
OCTAVIA 1997
->
The clicking of the valve cannot be heard because of the engine noise and can therefore only be checked. If the valve does not click:
Press
Readout on display: This test step is also activated on vehicles without AC system.
Readout on display: The valve must click. Note The clicking of the valve cannot be heard because of the engine noise and can therefore only be checked. If the valve does not click:
Press
Readout on display: The engine must stop. If the engine does not stop:
Press
Readout on display: The warning light for glow period must flash. If the warning light does not flash:
Press
Readout on display: Radiator fan control unit -J293- switches the radiator fan on and off for 30 seconds.
01-1 page 6
Self-diagnosis I
OCTAVIA 1997
01
Press
Readout on display: The relay must click. It is also possible to observe the relay switching on and off by the interior light becoming brighter and darker (caused by the high power consumption of glow plugs). If the relay does not click:
Press
Readout on display: The relay must click. If the relay does not click:
Test low heat output relay -J359- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
Readout on display: The relay must click. If the relay does not click:
Test high heat output relay -J360 - Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
Readout on display: The fault lamp must flash. If the fault lamp does not flash:
Press
Readout on display:
Self-diagnosis I
01-1 page 7
01
OCTAVIA 1997
01-1 page 8
Self-diagnosis I
OCTAVIA 1997
01
01-2
Self-diagnosis II
Fault table
Note The fault table is ordered according to the 5-digit fault code on the left. The SAE code which is displayed on the right next to the fault code (e.g. P0107) can be ignored (at present only valid for USA). Explanations regarding fault types (e.g. open circuit or short-circuit to earth) Operating instructions for the vehicle system tester. If parts are output as faulty: First of all test all leads and plug connections to these components, as well as the earth connections according to current flow diagram. Only if no fault is detected here should the part be replaced. This applies in particular if faults are shown as sporadic (SP). If Info in literature appears in the display of the vehicle system tester - V.A.G 1552- look for the text required in the fault table under the fault code. Readout on -V.A.G 155216485 Air mass meter -G70 16684 Combustion misfiring detected 16685 Cyl. 1 combustion misfirings detected 16686 Cyl. 2 combustion misfirings detected 16687 Cyl. 3 combustion misfirings detected 16688 Cyl. 4 combustion misfirings detected Implausible sig16705 Engine speed sender - nal G28 16706 No signal Engine speed sender G28 Implausible signal Rectifying fault
Test air mass meter -G70 - Chap. 01-4, display group 003 Test compression 1.9/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 15.
Inspecting Engine speed sender -G28- Chap. 23-1 Inspecting Engine speed sender -G28- Chap. 23-1 Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test position of camshaft and sensor rotor 1.9/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 15. 16885 Vehicle speed signal Implausible signal
Self-diagnosis II
01-2 page 1
01
Readout on -V.A.G 155216944 Voltage supply 16946 Voltage supply 16947 Voltage supply 16955 Brake light switch -F 16989 Control unit defective 17552 Air mass meter -G70 17553 Air mass meter -G70 17554 Air mass meter -G70 17563 Intake manifold pressure sender -G71 17564 Intake manifold pressure sender -G71 17565 Intake manifold pressure sender -G71 17568 Intake manifold temperature sender -G72 17569 Intake manifold temperature sender -G72 17570 Fuel temperature sender -G81 17571 Fuel temperature sender -G81 17663 Coolant temperature sender -G62 17664 Coolant temperature sender -G62
OCTAVIA 1997
Rectifying fault
Implausible signal Voltage too low Voltage too high Implausible signal
Test cables to diesel direct injection system control unit - J248- ac-
cording to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test brake light switch - F- and brake pedal switch -F47- Chap.
01-4, display group 006
Test air mass meter -G70- Chap. 01-4, display group 003 Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test intake manifold pressure sender -G71- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test intake manifold pressure Chap. 01-4, display group 010 Test intake manifold temperature sender -G72- Chap. 01-4, display group 007
Short circuit to earth Open circuit/ Short circuit to positive Short circuit to earth Open circuit/ Short circuit to positive
Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
01-2 page 2
Self-diagnosis II
OCTAVIA 1997
1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Rectifying fault
01
Readout on -V.A.G 155217668 Unit injector solenoid valve cyl. 1 -N240 17669 Unit injector solenoid valve cyl. 1 -N240 17670 Unit injector solenoid valve cyl. 1 -N240 17671 Unit injector solenoid valve cyl. 2 -N241 17672 Unit injector solenoid valve cyl. 2 -N241 17673 Unit injector solenoid valve cyl. 2 -N241 17674 Unit injector solenoid valve cyl. 3 -N242 17675 Unit injector solenoid valve cyl. 3 -N242 17676 Unit injector solenoid valve cyl. 3 -N242 17677 Unit injector solenoid valve cyl. 4 -N243 17678 Unit injector solenoid valve cyl. 4 -N243 17679 Unit injector solenoid valve cyl. 4 -N243 17795 Control unit defective 17810 Exhaust gas recirculation valve -N18 17849 Exhaust gas recirculation valve -N18 17910 Fuel pump relay -J17 17911 Load signal for alternator terminal DF Short circuit to positive Open circuit or short circuit to earth Short circuit to positive Implausible signal Implausible signal Regulating limit exceeded Regulating limit not reached
Check unit injector Chap. 23-3 Test fuel supply 1.9/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 20
Check unit injector Chap. 23-3 Test fuel supply 1.9/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 20
Check unit injector Chap. 23-3 Test fuel supply 1.9/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 20
Check unit injector Chap. 23-3 Test fuel supply 1.9/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 20
Test exhaust gas recirculation valve -N18- with final control diagnosis Chap. 01-1
Self-diagnosis II
01-2 page 3
01
Readout on -V.A.G 155217931 Crash signal from airbag CU 17932 Fuel pump relay -J17 17948 Vehicle speed signal
OCTAVIA 1997
Rectifying fault
Implausible signal Open circuit or short circuit to earth Signal too high
Test airbag system Body Work; Rep. Gr. 01 Testing fuel pump relay -J17- Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
17954 Charge pressure control solenoid valve N75 17957 Charge pressure control solenoid valve N75 17958 Charge pressure 17964 Charge pressure control 17965 Charge pressure control 17977 Cruise control system switch -E45
Test vehicle speed signal Chapter 23-6 Test CAN databus lines Chapter 23-6 Test dash panel insert Electrical System; Rep. Gr. 90 Test charge pressure control solenoid valve -N75- with final control diagnosis Chap. 01-1
Open circuit or short circuit to earth Control difference Regulating limit not reached Regulating limit exceeded Implausible signal
Test charge pressure control solenoid valve - N75- with final control
diagnosis Chap. 01-1
Reading measured value block, display group 010 Chap. 01-4 Test charge pressure control 1.9/74 kW (TDI) Engine, Mechanical
Components; Rep. Gr. 21
17978 Engine control unit blocked1) 18008 Voltage supply terminal 15 18009 Voltage supply relay terminal 30 -J3172) 18017 Crash disconnect activated 18020 Engine control unit 18024 Glow period warning lamp -K29 18025 Glow period warning lamp -K29 Incorrectly coded Short circuit to positive Open circuit or short circuit to earth Voltage too low
Test immobiliser Electrical System; Rep. Gr. 96 Test voltage supply for diesel direct injection system control unit
-J248- Chap. 23-5
Implausible signal
Test diesel direct injection system relay -J322- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Replace airbag control unit Body Work; Rep. Gr. 69 Code diesel direct injection system control unit -J248- Chap. 23-5 Test glow period warning lamp -K29- with final control diagnosis
Chap. 01-1
01-2 page 4
Self-diagnosis II
OCTAVIA 1997
1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Rectifying fault
01
Readout on -V.A.G 155218026 Glow plug relay -J52 18027 Glow plug relay -J52 18039 Accelerator pedal position sender -G79 18040 Accelerator pedal position sender -G79 18043 Data BUS drive Short circuit to positive Short circuit to earth Signal too high
Test glow plug relay -J52 - with final control diagnosis Chap. 01-1
Voltage supply
Missing message from air conditioning system CU Missing message from airbag CU missing message form electron. CU
Test CAN databus lines Chapter 23-6 Read out air conditioning system control unit fault memory
Heating, Air conditioning; Rep. Gr. 01
Test CAN databus lines Chapter 23-6 Read out fault memory of airbag CU Body Work; Rep. Gr. 01 Test CAN databus lines Chapter 23-6 Read out fault memory of electrical system control unit Electrical
System; Rep. Gr. 90
18047 Implausible sig1/2 for accelerator nal pedal position sender G79+G185 18048 Control unit defective 18056 Data BUS drive 18057 Data BUS drive 18058 Data BUS drive defective
Test CAN databus lines Chapter 23-6 Read out fault memory of engine CU Chapter 01-1 Test CAN databus lines Chapter 23-6 Read out fault memory of ABS control unit Chassis; Rep. Gr. 45
Test CAN databus lines Chapter 23-6 Read out fault memory of dash panel insert Electrical System;
Rep. Gr. 90
18062 Read out fault memory of combiinstrument 18065 Air conditioning system inlet/outlet 18067 Radiator fan control 1 18071 Actuation of unit injector solenoid valve 18072 Actuation of unit injector solenoid valve 18073 Actuation of unit injector solenoid valve Short circuit to positive Electrical fault in the circuit Mechanical fault Short circuit to positive
Test radiator fan control with final control diagnosis Chap. 01-1 Check unit injector Chap. 23-3
Self-diagnosis II
01-2 page 5
01
Readout on -V.A.G 155218074 Unit injector solenoid valve cyl. 1 -N240 18075 Unit injector solenoid valve cyl. 2 -N241 18076 Unit injector solenoid valve cyl. 3 -N242 18077 Unit injector solenoid valve cyl. 4 -N243 18080 Radiator fan control 1 18090 Data BUS drive 18097 Data BUS drive
OCTAVIA 1997
Rectifying fault
Open circuit or short circuit to earth implausible message from ABS CU Implausible message from electron. CU Missing message from combiinstrument Implausible signal
Test CAN databus lines Chapter 23-6 Read out fault memory of ABS control unit Chassis; Rep. Gr. 45 Test CAN databus lines Chapter 23-6 Read out fault memory of electrical system control unit Electrical
System; Rep. Gr. 90
Test CAN databus lines Chapter 23-6 Test accelerator pedal position sender -G79- Chap. 01-4, display
group 002
Short circuit to 19459 Low heat output relay - positive J359 19461 High heat output relay -J360 19463 Camshaft pos. sensor => Sender -G40 No signal
Test low heat output relay -J359- with final control diagnosis
Chap. 01-1
Test high heat output relay -J360- with final control diagnosis
Chap. 01-1
Test position of camshaft and sensor rotor 1.9/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 15. Signal outside tolerance
flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations gine, Mechanical Components; Rep. Gr. 15.
01-2 page 6
Self-diagnosis II
OCTAVIA 1997
1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Rectifying fault
01
Readout on -V.A.G 155219560 Intake manifold flap change-over valve N239 19561 Intake manifold flap change-over valve N239 19586 Exhaust gas recirculation system 19587 Exhaust gas recirculation system
1)
Test intake manifold flap changeover valve -N239- with final control
diagnosis Chap. 01-1
Open circuit or short circuit to earth Regulating limit not reached Regulating limit exceeded
Testing Exhaust gas recirculation valve -N18- Chap. 23-1 Inspecting exhaust gas recirculation Chap. 23-4
2)
When attempting to start with a non-adapted key a static fault is stored in the memory. If a subsequent start attempt occurs with an adpated key the fault is changed to a sporadic fault. Relay for voltage supply terminal 30 -J317- is identical with relay for diesel direct injection system -J322-.
Self-diagnosis II
01-2 page 7
01
OCTAVIA 1997
01-2 page 8
Self-diagnosis II
OCTAVIA 1997
01
01-3
Self-diagnosis III
Meaning of 8-digit numerical block for readiness code in display field 2 1 2 3 4 5 6 7 1 1 0 0 0 0 0 8 0 Ignore Ignore Ignore Ignore Ignore Diagnosis of other systems Diagnosis of fuel system Ignore Meaning
Self-diagnosis III
01-3 page 1
01
OCTAVIA 1997
Meaning of 8-digit numerical block for readiness code in display field 4 1 2 3 4 5 6 7 0 0 0 0 0 0 0 8 0 Ignore Ignore Ignore Ignore Ignore Ignore Ignore Diagnosis of exhaust gas recirculation system Meaning
If the specified values are not reached, generate readiness code 01-3 page 2.
Press key. Select function 06 End output and switch ignition off.
Test conditions
All electrical consumers such as lights and rear window heater switched off
Procedure
Certain work steps have to be carried out twice, in order to achieve the readiness code.
Enter function
The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
01-3 page 2
Self-diagnosis III
OCTAVIA 1997
01
Press
Select function
firm entry with Q . Note Readiness code is erased each time the fault memory is erased. Readout on display: Note If the ignition is switched off during Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Vehicle system test The fault memory is erased ->
Press
Self-diagnosis III
01-3 page 3
01
Readout on display:
OCTAVIA 1997
In this speed range, the exhaust gas recirculation is active and the control difference is checked. (Condition for generation of readiness code for exhaust gas recirculation).
1 -> 93.2 C
Press Enter
C. 0 1 7 for display group 017 and read readiReading measured value block 00000000 00000110 10000000 17 -> 00000000
ness code. Readout on display: Specification in display field 2: 00000110 Specification in display field 4: 00000000
Press . If the specified values are not reached, repeat procedure for generating readiness code 01-3 page 2.
Enter function
confirm entry with Q . The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
01-3 page 4
Self-diagnosis III
01
Press
Readiness code was successfully generated, if no fault is stored after repeating the test procedure in the fault memory of the engine control unit and if the following appears in the channel 017.
Self-diagnosis III
01-3 page 5
01
OCTAVIA 1997
01-3 page 6
Self-diagnosis III
OCTAVIA 1997
01
01-4
Self-diagnosis IV
Test conditions
Coolant temperature must be at least 75 C. All electrical consumers, e.g. lights and rear window
heater, must be switched off.
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
Rectifying fault
Check unit injector Chap. 23-3. Warm up engine by running at high revs and repeat test. Check unit injector Chap. 23-3.
Self-diagnosis IV
01-4 page 1
01
OCTAVIA 1997
Display group 002 in idle (engine warm, coolant temperature not below 75 C)
Read measured value block 2 xxx rpm 1 xxx.x % 2 xxx 3 xxx.x C 4 < Display field Coolant temperature Operating position Accelerator pedal position Engine speed Specification 75,0110.0 C 010 0,0 % 800950 rpm Analysis -- 01-4 page 2 01-4 page 2 --< Readout on display
Rectifying fault
Display group 003 in idle (engine warm, coolant temperature not below 75 C)
Read measured value block 3 xxx rpm 1 xxx mg/s 2 xxx mg/s 3 xxx % 4 < Display field On/off ratio (actuation) of exhaust gas recirculation valve drawn in air mass (actual value) drawn in air mass (nominal value) Engine speed Specification 5070 % Analysis --< Readout on display
01-4 page 2
Self-diagnosis IV
OCTAVIA 1997
01
Analysis: Display group 003, display field 2 - inducted air mass (set value)
Rectifying fault
Engine too cold, warm up engine by running at high revs and repeat test.
Analysis: Display group 003, display field 3 - inducted air mass (actual value)
Rectifying fault
Test exhaust gas recirculation Chap. 23-4. Test intake system for leaks. Warm up engine by running at high revs and repeat test. Engine idles for too long, briefly blip throttle. Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Display group 004 in idle (engine warm, coolant temperature not below 75 C)
Read measured value block 4 xxx rpm 1 xx.x b. TDC 2 xx.x KW 3 xx.x KW 4 < Display field Synchronizing angle Fuel delivery duration (set value) Commencement of injection (set value) Engine speed Specification -5+4 KW 3,07.0 KW 4 BTDC1 ATDC 800950 rpm Analysis 01-4 page 3 -- 01-4 page 3 --< Readout on display
Analysis: Display group 004, display field 2 - commencement of injection (set value)
Rectifying fault
Engine too cold, warm up engine by running at high revs and repeat test.
Rectifying fault
Check position of camshaft and sensor rotor 1.9/74 (TDI) Engine, Mechanical Components; Rep. Gr. 15.
Self-diagnosis IV
01-4 page 3
01
OCTAVIA 1997
Display group 006 in idle (engine warm, coolant temperature not below 75 C)
Read measured value block 6 xxx km/h 1 xxx 2 xx.x % 3 xxx 4 < Display field Operating state of cruise control Accelerator pedal position Status of the brake and clutch pedal switch Vehicle speed Specification xxx 0% 000 0 km/h Analysis 01-4 page 4 01-4 page 2 01-4 page 4 --< Readout on display
Analysis: Display group 006, display field 2 Status of brake and clutch pedal switch
Meaning, if display positions = 1 X X X 1 1 1 Operating position Brake light switch -F- closed (brake pedal operated) Brake pedal switch -F47- opened (brake pedal operated) Clutch pedal switch -F36- opened (clutch pedal operated)
Analysis: Display group 006, display field 4 - Operating condition of cruise control
Display 0 1 255 Operating position Vehicle with cruise control system, cruise control system switched off Vehicle with cruise control system, cruise control system switched on Vehicle without cruise control system, or cruise control system function in engine control unit not activated
01-4 page 4
Self-diagnosis IV
OCTAVIA 1997
01
Display group 007 with ignition switched on (engine cool and standing)
Read measured value block 7 xxx.x C 1 xxx % 2 xxx.x C 3 xxx.x C 4 < Display field Coolant temperature Intake manifold temperature Status of the fuel cooling Fuel temperature
1)
Specification approx. ambient temperature 1) approx. ambient temperature 1) 0% approx. ambient temperature 1)
It is not possible to give a nominal value indication for temperatures. Once the engine has cooled down the temperatures of the fuel, intake manifold and coolant must approximately correspond with the ambient temperature. If there is a marked value difference check the relevant sender.
Rectifying fault
Rectifying fault
Rectifying fault
Self-diagnosis IV
01-4 page 5
01
OCTAVIA 1997
Display group 010 in idle (engine warm, coolant temperature not below 75 C)
Read measured value block 10 xxx rpm 1 xxxx mbar 2 xxxx mbar 3 xxx % 4 < Display field Accelerator pedal position Charge pressure (actual value) Atmospheric pressure drawn in air mass (actual value) Specification 0,0 % 900...1150 mbar 900...1100 mbar 210...370 mg/s Analysis 01-4 page 2 ---- 01-4 page 3 < Readout on display
Display group 011 in idle (engine warm, coolant temperature not below 75 C)
Read measured value block 11 xxx rpm 1 xxxx mbar 2 xxxx mbar 3 xxx % 4 < Display field On/off ratio (actuation) of solenoid valve for charge pressure control -N75Charge pressure (actual value) Charge pressure (specified value) Engine speed Specification 20...50 % Analysis --< Readout on display
-------
Display group 013 in idle (engine warm, coolant temperature not below 75 C)
Read measured value block 13 x.xx mg/s 1 x.xx mg/s 2 x.xx mg/s 3 x.xx mg/s 4 < Display field Smooth running control injected quantity cylinder 4 Smooth running control - injected quantity cylinder 3 Smooth running control - injected quantity cylinder 2 Smooth running control - injected quantity cylinder 1 Specification -2,80+2.80 mg/s Analysis 01-4 page 7 01-4 page 7 01-4 page 7 01-4 page 7 < Readout on display
01-4 page 6
Self-diagnosis IV
OCTAVIA 1997
01
Analysis: Display group 013, display field 1 to 4 - idle smooth running control
The injection system has an idle smoothness regulator. It is possible to detect differences in performance between individual cylinders (part tolerances, injector flow, compression etc.) and to compensate for these by selectively metering the quantity injected in the idling speed range. Differences are detected in the idling speed range on the basis of the signal supplied by the engine speed sender which supplies four signals to the control unit for each crankshaft revolution. If the signals have the same rhythm, the cylinder have the same output. If a cylinder has a lower output, the crankshaft will need more time for the next half crankshaft rotation. As opposed to this a high output cylinder will accelerate the crankshaft to such an extent that it will need less time. Once the control unit has identified a deviation, the relevant cylinder will immediately be supplied with a greater or smaller injection rate until the engine again runs smoothly. + mg/s: The relevant cylinder has less output and is therefore supplied with more fuel. - mg/s: The relevant cylinder has more output and is therefore supplied with less fuel.
Meaning, if display positions = 1 X X X X X X X X 1 1 1 1 1 Additional heating deactivated, because: Coolant temperature greater than 7075 C or intake air temperature greater than +5C Generator defective Battery voltage below 9 V Engine speed less than 800 rpm Engine start within the last 10 seconds
Self-diagnosis IV
01-4 page 7
01
OCTAVIA 1997
Meaning, if display positions = 1 X X X 1 1 1 X X X X X Additional heating deactivated, because: Coolant temperature sender -G62 - or Intake manifold temperature sender -G72 - defective Ignore Ignore
Analysis: Display group 016, display field 3 Control of the heating elements
Meaning, if display positions = 1 X 1 X 1 Operating position Low heat output relay -J359- switched on High heat output relay -J360- switched on
Analysis: Display group 016, display field 4 - supply voltage of engine control unit
Rectifying fault
Test generator and battery voltage, charge battery Electrical System; Increase engine speed slightly for a few minutes and switch off additional
consumers.
Test supply voltage of engine control unit Chap. 23-5. Rectify any current drain. Test voltage regulator, replace if necessary Electrical System; Rep. Gr.
27.
01-4 page 8
Self-diagnosis IV
OCTAVIA 1997
01
Analysis: Display group 018, display field 1 through 4 - Display of the conditon of the unit injectors
Rectifying fault
Check unit injector Chap. 23-3. Test fuel supply 1.9/74 kW (TDI) Engine, Mechanical Components;
Rep. Gr. 20.
Analysis: Display group 022, display field 1 - operating state of cruise control system
Operating condition of the cruise control system 1 9 0 Vehicle with CCS - CCS switched off Vehicle with CCS - CCS switched on Vehicle without CCS, or CCS function in engine control unit not activated
Self-diagnosis IV
01-4 page 9
01
OCTAVIA 1997
Analysis: Display group 022, display field 2 - operating state of cruise control system
A
Cruise control Switch B on ON Switch B on RES Switch A operated Switch B to OFF before operating point Switch B to OFF locks Brake pedal depressed Clutch pedal depressed
N23-0199
Display group 004 under full load (test drive in 2nd gear coolant temperature not below 75C)
Read measured value block 4 xxx rpm 1 xx.x b. TDC 2 xx.x KW 3 x.xx KW 4 < Display field Synchronizing angle Fuel delivery duration (set value) Commencement of injection (set value) Engine speed Specification -5...4 KW 1923 KW 16 BTDC23 BTDC 28003200 rpm Analysis ---------
01-4 page 10
Self-diagnosis IV
OCTAVIA 1997
01
Display group 008 under full load (test drive in 2nd gear coolant temperature not below 75C)
Read measured value block 8 xxx rpm 1 xx.x mg/s 2 xx.x mg/s 3 xx.x mg/s 4 < Display field Injection rate limit based on drawn in air mass (smoke prevention) Injection rate limit based on engine speed (torque limit) Injection rate (driver's instruction) Engine speed Specification 44,052.0 mg/s Analysis 01-4 page 11 01-4 page 11 01-4 page 11 ---
Analysis: Display group 008, display field 2 - Injection rate (driver's instruction)
Rectifying fault
Repeat test at full throttle. Test accelerator pedal position sender -G79- Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations.
Analysis: Display group 008, display field 3 - Injection rate limit over engine speed
Rectifying fault
Analysis: Display group 008, display field 4 - Injection rate limit (smoke prevention)
Rectifying fault
Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Find Test exhaust gas recirculation Chap. 23-4.
Self-diagnosis IV
01-4 page 11
01
OCTAVIA 1997
Display group 011 under full load (test drive in 2nd gear coolant temperature not below 75 C)
Read measured value block 11 xxx rpm 1 xxxx mbar 2 xxxx mbar 3 xxx % 4 < Display field On/off ratio (actuation) of solenoid valve for charge pressure control -N75Charge pressure (actual value) Charge pressure (specified value) Engine speed Specification 55...80% Analysis 01-4 page 12 01-4 page 12 ----< Readout on display
Analysis: Display group 011, display field 3 - Charge pressure (actual value)
Possible cause of fault Charge pressure control defective Leaking intake manifold Damaged turbocharger
Rectifying fault
Analysis: Display group 011, display field 4 - On/off ratio (actuation) of solenoid valve for charge pressure control -N75-
Possible cause of fault Charge pressure control defective Charge pressure is not controlled
Rectifying fault
01-4 page 12
Self-diagnosis IV
OCTAVIA 1997
01
Rectifying fault
Self-diagnosis IV
01-4 page 13
01
OCTAVIA 1997
01-4 page 14
Self-diagnosis IV
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OCTAVIA 1997
1.9 l/74 kW (TDI) Engine, Fuel Injection and Glow Plug System
23
23-4
6 13
12
11
10
8
S20-0123
Test sequence
The exhaust gas recirculation function is checked in function 04 (basic setting). As a result of this procedure the exhaust gas recirculation valve is pulsed every 10 seconds, so that the extreme values for the exhaust gas recirculation (air mass meter) can be read off in measured value block 003 in display field 3.
23-4 page 1
23
OCTAVIA 1997
1.9 l/74 kW (TDI) Engine, Fuel Injection and Glow Plug System
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics Chapter 01-1.
1.9 l/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 26. 23-4 page 1. 01-1.
Inspect the connection diagram for the vacuum hoses Test exhaust gas recirculation valve -N18- Chap.
23-4 page 2
OCTAVIA 1997
23
23-5
Test conditions
Switch off ignition. Connect test box -V.A.G 1598/31- to the wiring loom
of the engine control unit Chap. 23-3.
Switch on ignition. Measure once again the voltage between the bushes.
23-5 page 1
23
Test box - V.A.G 1598/ 31-, bush 1, 2 + 4, 5 37 + 4, 5
OCTAVIA 1997
Replacing diesel direct injection system control unit -J248Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
Note Part No. of control unit and coding. Enter function 06 End output and confirm entry with
Q.
Switch off ignition. Remove the cooling water tank cover Body Work;
Rep. Gr. 66.
Release the connector catches and unplug the connectors of the diesel direct injection control unit - J248-.
Perform coding of diesel direct injection system control unit -J248- 23-5 page 3.
Adapt new diesel direct injection system control unit On vehicles fitted with CCS: Activate CCS 23-5
page 4.
23-5 page 2
OCTAVIA 1997
23
Coding diesel direct injection system control unit -J248If the code displayed does not match the vehicle or if the diesel direct injection system control unit -J248- has been replaced, it is then necessary to code the control unit as follows. Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
The vehicle system tester -V.A.G 1552 - displays the control unit identification, e. g.:
23-5 page 3
23
OCTAVIA 1997
Test condition
Procedure
Confirm the entry with Q . Enter function 06 End output and confirm entry with
Q.
23-5 page 4
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OCTAVIA 1997
28
Test conditions
Battery voltage at least 11.5 volts Diesel direct injection system control unit -J248 - O.K. Fuses in fuse holder on battery are O.K.
Test sequence
2 1
2 1
Remove glow plug connectors from the glow plugs. Connect Hand multimeter for voltage measurement to
a glow plug connector and engine mass.
S23-0119
During the simulated preheating process the glow period warning lamp -K29- must light up. If the warning lamp does not light up:
28-1 page 1
28
Checking glow plugs
OCTAVIA 1997
Test condition
Remove glow plug connectors from the glow plugs. Connect the wire of the diode test lamp to battery positive (+).
Replace glow plug. If necessary remove and install glow plugs with flexible-head wrench (e.g. -3220-). Tightening torque: 15 Nm
S28-0118
28-1 page 2