38613476 Workshop Manual Octavia Engine Fuel Injection 1 9tdi

Service

Workshop Manual

Service Department. Technical InformationS00.5111.50.20 Edition 08.96

1.9-ltr. / 66 kW (TDI) EngineFuel Injection and Glow Plug System

The Workshop Manual is intended only for use within the ŠKODAOrganisation; it is not permitted to pass it on to third parties.

© 1996 ŠKODA, automobilová a.s.

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Self-Diagnosis 01

Edition 02.99

Test of vehicle systems HELPSelect function XX

X faults recognized

Test of vehicle systems HELPSelect function XX

Test of vehicle systems →

Fault memory is erased

Readout in display:

- Press the keys 0 and 2 for the function „In-terrogate fault memory“ and confirm the en-try with the key Q.

The number of stored faults appears in the dis-

play.

If one or several faults are stored:

The stored faults are displayed one after theother.

After the stored faults have been displayed, the

following readout appears:

- Press the keys 0 and 5 for the function „Erasefault memory“ and confirm the entry with thekey Q.

Readout in display:

Note:

If you have switched off the ignition between„Interrogating fault memory“ and „Erasing faultmemory“, the fault memory is not erased.

- Press the → key.

- Press the keys 0 and 6 for the function „Endoutput“ and confirm the entry with the key Q.

- Carry out a road test. During the road test,once again interrogate the fault memory. Nofurther faults should be displayed.

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Self-Diagnosis 01

Edition 02.99

Readout on V.A.G 1552

Fault number Possible cause of fault Possible effects Rectifying fault

old

00522

Coolant temperaturesender -G62

Short circuit toearth

Open/shortcircuit to positive

00527

Intake manifold tem-perature sender -G72



00532

Supply voltage

Implausible signal

as appropriate

Voltage supply tml.15

Voltage too low

new

17663

17664

17568

17569

18008

♦ -G62 faulty♦ Cable has short circuit to

earth

♦ -G62 faulty♦ Open circuit in wiring or

cable has short circuit topositive


earth


short circuit to positive

♦ Control unit was con-nected when ignition on

♦ Open circuit in wiring orshort circuit

♦ Voltage not present whenignition on (terminal 15)

♦ Diesel direct injection sys-tem control unit -J248faulty

♦ Voltage supply relay termi-nal 30 (J322) faulty

♦ Black exhaust when start-ing

♦ Engine preheater does notoperate

♦ Preglowing always oper-ates for about 20 seconds

♦ Engine preheater does notoperate

♦ Engine does not start♦ Engine stops

- Test coolant temperaturesender ⇒ page 23-43

- Test intake manifold tem-perature sender⇒ page 23-25

- Erase fault memory andcontinue checking vehicle

- Test voltage supply of die-sel direct injection systemcontrol unit ⇒ page 23-38

- Test voltage supply of ter-minal 15

⇒ Current Flow Diagrams,Electrical Fault Findingand Fitting Locationsbinder

- Replace control unit⇒ page 23-20

- Test voltage supply of die-sel direct injection systemcontrol unit ⇒ page 23-38

01 Self-Diagnosis

Edition 02.99



old

00539

Fuel temperaturesender -G81



00542

Needle lift sender-G80


Implausible signal


new

17570

17571

17653

17654

17655


earth



♦ Connector for injectionpump separated


short circuit

♦ Fuel supply (was) inter-rupted: tank has runempty, feed line or filterblocked, system drawingin air

♦ (Sporadic) open circuit inwiring to fuel cut-off valve

♦ Sender plate of enginespeed sender bent orloose

♦ -G80 faulty

♦ Injection pump faulty

♦ -G80 faulty♦ Sporadic open circuit in

wiring (cable break)

♦ Reduced output

♦ Several faults stored♦ Engine stops

♦ Glow indicator lampflashes

♦ Rough engine running♦ Reduced output

♦ Fault 00550 Commence-ment of injection controlpossible

♦ Misfiring, jerking

♦ Engine stops♦ Misfiring

♦ Misfiring at exactly3000 rpm

♦ Misfiring, jerking (particu-larly at high revs)

♦ Fault 01268 quantity ad-juster control differencestored

♦ Irregular engine running,misfiring

♦ No throttle response afteroverrun

♦ Glow indicator lampflashes

♦ Misfiring, jerking♦ Reduced output

- Test fuel temperaturesender ⇒ page 23-30

- Check plug connection forinjection pump

- Test needle lift sender⇒ page 23-42

- Check fuel system

- Check cable connectionand plug connection at in-jection pump

- Take off oil pan and in-spect sender plate

- Replace needle lift sender

- Replace injection pump


Self-Diagnosis 01

Edition 02.99



old

00545

Engine/gearbox elec-trical connection 1)

00550

Commencement ofinjection control

Control difference

new

-

17656


♦ Commencement of deliv-ery not o.k.

♦ Adjustment travel of injec-tion pump blocked (dirt,swarf)

♦ Engine was stalled (withinthe last 50 starts)

♦ Fuel feed (was) inter-rupted: tank has runempty, feed line or filterblocked, system drawingin air

♦ Open circuit in wiring tocommencement of injec-tion valve -N108

♦ Commencement of injec-tion valve -N108 worn

♦ Hard gearshifts

♦ Poor performance athigher revs

♦ Engine difficult to start

♦ Poor performance athigher revs

♦ Fault 00542 Needle liftsender implausible signalmay be stored

♦ Engine clatters when id-ling as commencement ofinjection constantly ”ad-vanced”

♦ Several faults may bestored

♦ No constant commence-ment of injection possibleat ”Basic setting” (displayblock 2 varies over morethan 10 readouts)

♦ Irregular engine running,poor performance

- Test signals from/to auto-matic gearboxA - Signal for gearshift

- Test and set commence-ment of injection⇒ page 23-13

- Test injection timing con-trol range ⇒ page 23-28

- Erase fault memory, con-tinue checking vehicle

- Check fuel system

- Test commencement ofinjection valve⇒ page 23-29

- Test fuse

- Replace commencementof injection valve

1) Not available at present.

01 Self-Diagnosis

Edition 02.99



old

00553

Air mass meter -G70

Implausible signal

Open/shortcircuit to earth

Short circuit to posi-tive

Supply voltage

00575

Intake manifold pres-sure

Control difference

if appropriate

Charge pressureControl difference

new

16485

17552

17553

17554

17958

♦ Engine was stalled (withinthe last 50 starts)

♦ Battery weak

♦ Sporadic open circuit inwiring (cable break) toneedle lift sender -G80

♦ Air filter blocked♦ Vacuum hoses of exhaust

gas recirculation incor-rectly connected or me-chanical EGR valve con-stantly open

♦ Air mass meter faulty


short circuit to earth




♦ Hoses wrongly connected,not fitted on, blocked,leaking

♦ Turbocharger vacuum unitfaulty

♦ Charge pressure controlsolenoid valve -N75 faulty

♦ Poor performance♦ Air mass constantly indi-

cated in measured valueblock

♦ Misfiring, jerking♦ Fault 00542 Needle lift

sender implausible signalpossible or open/short cir-cuit to positive

♦ Irregular idling, poor per-formance

♦ Poor performance, jerking

♦ Reduced output♦ Black exhaust possible

when accelerating fromlow revs

♦ Sudden drop in power♦ Reduced output

- Erase fault memory, con-tinue checking vehicle

- Test battery


- Inspect intake system- Inspect vacuum hoses

⇒ page 23-37

- Test air mass meter⇒ page 23-35

- Test charge pressure⇒ page 23-22

- Inspect charge pressurehoses ⇒ page 23-27

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01 Self-Diagnosis

Edition 02.99



old

00741

Brake pedal monitor-ing

Implausible signal

00765

Modulating pistonmovement sender-G149

00777

Accelerator pedal po-sition sender -G79

Signal too large

Voltage supply

Implausible signalas appropriate

Accelerator pedal po-sition sender 1/2-G79+-G185 1)

Implausible signal

Short circuit to posi-tive

01044

Engine control unitincorrectly coded

new

-

17762

18039

18040

18047

-

18020

♦ Switch incorrectly set♦ Open circuit in wiring♦ -F or -F47 faulty♦ Fuse faulty♦ Both brake lights faulty

♦ 10-pin connector for injec-tion pump separated

♦ Injection pump faulty♦ Open circuit in wiring or

short circuit

♦ Open circuit in wiring♦ -G79 faulty (idling switch)


♦ Open circuit in wiring♦ -G79 faulty (idling switch)

♦ Short circuit to positive♦ -G79 faulty

♦ Invalid control unit coding

♦ Preglow indicator lampflashes

♦ Fuse or brake light faulty

♦ Several faults stored♦ Engine stops♦ Drivability problems♦ Engine stops

♦ Speed governed to approx.1100 rpm as safety meas-ure

♦ No throttle response♦ Preglow indicator light

flashes♦ Fast idling speed

♦ Preglow indicator lightflashes

- Test -F and -F47 and set⇒ page 23-44

- Test fuse and brake light

- Inspect plug connectionof injection pump

- Test modulating pistonmovement sender⇒ page 23-45

- Test accelerator pedal po-sition sender⇒ page 23-47

- Code control unit⇒ page 01-23

1) Incorrect fault text readout. The correct readout is:Accelerator pedal position sender -G79

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Self-Diagnosis 01

Edition 05.97

Test of vehicle systems Q03 - Final control diagnosis

Final control diagnosis →

Start of injection valve -N108


EGR valve -N18


AC compressor cut-off

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

Readout in display:

- Confirm the entry with the key Q.

Readout in display:

When the valve is actuated, this results in aclearly audible change in the combustionnoise (diesel noise).

If no change in the combustion noise can beheard:

- Test injection timing device control range⇒ page 23-28.


Readout in display:

The valve should click.

Note:

The clicking of the valve cannot be heard be-cause of the engine noise and should thereforebe felt by touching.

If the valve does not click:

- Test EGR valve ⇒

page 23-34.


Readout in display:

What is tested is the AC compressor cut-off.

The test step is also displayed in the case ofvehicles without air conditioning.

The AC compressor should stop within 5seconds (visual inspection with electrictorch), and then start and stop again approxi-mately every 5 seconds.

If the AC compressor is not switched off:

- Test AC compressor cut-off ⇒

page 23-49.

01 Self-Diagnosis

Edition 05.97


Fuel cut-off valve -N109


Charge pressure control solenoid valve -N75


Glow plugs relay -J52


Glow period warning light -K29


Readout in display:

The engine should stop.

If the engine does not stop:

- Switch off the ignition.

- Unscrew fuel cut-off valve and clean anymetal swarf and dirt.

- Repeat final control diagnosis; if the engineagain does not stop, replace fuel cut-offvalve.


Readout in display:

The solenoid valve should click.

Note:

It is very difficult to hear the clicking of the valveand it should therefore be checked by touching.

If the solenoid valve does not click:

- Test charge pressure control solenoid valve⇒ page 23-24.


Readout in display:

The relay should click.

Because of the high power consumption ofthe glow plugs, it is also possible to checkthat the relay switches on and off by observ-ing how the interior light becomes dimmerand then brighter.

If the relay does not click:

- Test glow plugs relay⇒Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder


Readout in display:

The warning light should flash.

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Fuel Preparation/Fuel Injection 23

Edition 05.97

Servicing diesel direct injec-tion system

Safety precautions

Pay attention to the following precautions in or-der to avoid injuries to persons and/or damageto the fuel injection and glow plug system:

♦ Do not disconnect and connect the cablesof the glow plug and fuel injection system -also not of test equipment - unless the igni-tion is switched off.

♦ To operate the engine at starting speed with-out it actually starting, e.g. for testing thecompression pressure, unplug the connec-tor at the injection pump.

♦ Before disconnecting the battery, determinethe code of radio sets with anti-theft coding.

♦ The ignition should always be switched offbefore disconnecting and connecting thebattery otherwise the diesel direct injectionsystem control unit may be damaged.

Rules for cleanliness

Pay careful attention to the following „5 rules“for cleanliness when carrying out work on thefuel supply/fuel injection system:

♦ Thoroughly clean connection points and thesurrounding area before disconnecting.

♦ Place removed parts down on a clean sur-face and cover over. Do not use fluffingcloths!

♦ Carefully cover over or seal opened compo-nents if repairs are not carried out immedi-ately.

♦ Install only clean parts:Do not remove replacement parts from theirwrapping until just before installing.Do not use parts which have been storedunwrapped (e.g. in tool boxes etc.).

♦ If the system is opened:Avoid working with compressed air, if possi-ble.Avoid moving the vehicle, if possible.

♦ In addition, ensure that no diesel fuel flowsonto the coolant hoses. If this happens, it isthen necessary to clean the hoses againwithout delay. Replace any hoses which havesuffered damage.

23 Fuel Formation / Fuel Injection

Edition 03.98

Summary of fitting locations 07.97

Components A to E are not shown on the sum-mary illustration.

A - Relay for diesel direct injection sys-tem (J322)♦ Electrical centre ⇒ page 23-2.1, Fig. 1

B - Glow plug relay (J52)♦ Electrical centre ⇒ page 23-2.1, Fig. 1

C - Accelerator pedal position sender(G79)♦ In footwell at accelerator pedal

⇒ page 23-6

D - Brake light switch (F) and brake pedalswitch (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

Fuel Formation / Fuel Injection 23

Edition 03.98

1 - Mechanical exhaust gas recirculationvalve

2 - Injection nozzle with needle lift sender(G80)

3 - Diesel direct injection system controlunit (J248)♦ With altitude sender (F96)

4 - Electromagnetic EGR valve (N18)

5 - Charge pressure control solenoidvalve (N75)

6 - Air mass meter (G70)

7 - High heating capacity relay (J360)♦ Only for models with optional equip-

ment

8 - Low heating capacity relay (J359)♦ Only for models with optional equip-

ment

9 - Coolant temperature sender (G62)

10 - Engine speed sender (G28)

11 - Plug connection♦ 2-pin♦ For needle lift sender (G80)

12 - Plug connection♦ 3-pin♦ For engine speed sender (G28)

13 - Plug connection♦ 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 injectionpump♦ With fuel temperature sender♦ With quantity adjuster (N146)♦ With modulating piston movement

sender (G149)

17 - Intake manifold pressure sender (G71)and intake manifold temperaturesender (G72)

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 pedalswitch (F47)

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Edition 03.98

1 - Intake fitting♦ With mechanical exhaust gas recir-

culation valve♦ With intake manifold flap

2 - Intake manifold flap changeover valve(N239)

3 - Injection nozzle with needle lift sender(G80)

4 - Diesel direct injection system controlunit (J248)♦ With altitude sender (F96)

5 - Electromagnetic EGR valve (N18)

6 - Charge pressure control solenoidvalve (N75)

7 - Air mass meter (G70)

8 - High heating capacity relay (J360)♦ Only for models with optional equip-

ment

9 - Low heating capacity relay (J359)♦ Only for models with optional equip-

ment

10 - Coolant temperature sender (G62)

11 - Engine speed sender (G28)

12 - Plug connection♦ 2-pin♦ For needle lift sender (G80)

13 - Plug connection♦ 3-pin♦ For engine speed sender (G28)

14 - Plug connection♦ 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)

15 - Commencement of injection valve(N108)

16 - Fuel cut-off valve (N109)

17 - Fuel metering control of injectionpump♦ With fuel temperature sender♦ With quantity adjuster (N146)♦ With modulating piston movement

sender (G149)

18 - Intake manifold pressure sender (G71)and intake manifold temperaturesender (G72)

Fig. 2 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 pedalswitch (F47)

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23 Fuel Preparation/Fuel Injection

Edition 05.97

Servicing injection pump

♦ Pay attention to safety precautions⇒ page 23-1

♦ Pay attention to rules for cleanliness⇒ page 23-1

♦ Removing and installing injection pump⇒ page 23-8

♦ Dynamic test and setting of start of injection⇒ page 23-13

Note:

Fuel hoses at the engine must be secured onlywith spring-strap clips. It is not permitted to useclamp-type or screw-type clips.

1 - Stretch bolt♦ Always replace♦ 20 Nm + 1/

4 turn (90°)

2 - Injection pump gear

3 - Hub nut♦ On no account slacken

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Edition 03.98

- Remove the top toothed belt guard, thevacuum pump and the cylinder head cover.

- Remove sound-absorbing pan and air guidepipe between intercooler and turbocharger.

Engine installed

- Take off cover at inspection opening.

- Position the crankshaft to TDC of cylinder 1-arrow-.

Engine placed down on floor

- Screw in setting device for TDC point (MP1-313, as shown in the illustration.

- Set setting device to 96 mm -arrow- (the leftnotch of the vernier -arrow A- is the refer-ence point).

- Rotate crankshaft until TDC marking -arrowB- on the flywheel is aligned with the edge ofthe setting device.

Engine attached to engine holder MP 1-202

- Position flexible steel ruler (marking tool)against the circumference of the flywheel.

- Measure exactly 100 mm from the TDCmarking -arrow A- and make a mark -arrowB- as an aid with marking tool.


Edition 03.98

- Screw in adjusting device for TDC MP 1-313as shown in illustration.

- Set adjusting device to 91.4 mm (the left-hand notch of the vernier -arrow A- is thereference point).

- Rotate crankshaft until the help marking onthe flywheel is aligned with the edge of theadjusting device -arrow B-.

For all cases

- Lock the camshaft with the adjustingstraightedge MP 1-312.

- The adjusting straightedge should be cen-tred as follows: Rotate the locked camshaftuntil one end of the adjusting straightedgemakes contact with the cylinder head. Use afeeler gauge to measure the clearance pro-duced at the other end of the adjustingstraightedge. Insert a feeler gauge equal tohalf the clearance measured, between ad-justing straightedge and cylinder head. Now,rotate the camshaft until the adjustingstraightedge touches the feeler gauge. In-sert a second feeler gauge with the samethickness at the other end between adjust-ing straightedge and cylinder head.

- Slacken the bolts -1- attaching the injectionpump sprocket.

Notes:

♦ Use the locking pin 3359 for counterholdingthe injection pump sprocket ⇒ page 23-12,Fig. A13-0052.

♦ Always moisten the locking pin with oil. Usea mirror to make it easier to insert the pin.

♦ If it is not possible to lock the injection pumpsprocket with the locking pin, rotate thecrankshaft so that the holes for the lockingpin are aligned. Then, slacken the bolts ofthe injection pump sprocket and, only now,position the crankshaft to TDC.

♦ On no account, slacken the central nut -2- ofthe injection pump sprocket otherwise thebasic setting of the injection pump will be al-tered and can no longer be set with work-shop tools.


Edition 03.98

- Unscrew the nut of the tensioning pulley.

- Take the toothed belt off the toothed beltsprockets of the camshaft and injectionpump.

- Unplug the connector for the electrical con-nections of the injection pump.

- Unscrew the securing bolts -1- at the mount-ing bracket.

Note:

On no account, slacken the central nut -2- ofthe injection pump sprocket otherwise the ba-sic setting of the injection pump will be alteredand can no longer be set with workshop tools.

- Then, unscrew the securing bolts from therear support -arrow-.

- Take off the injection pump.

Installing

- Insert the injection pump into the mountingbracket and first of all attach the bolt at therear support with the tapered nut.

- Insert the front securing bolts and tighten thebolts to 25 Nm.

- Loosely secure the injection pump sprocketat the hub with new securing bolts (do notrotate injection pump sprocket).

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Edition 03.98

Note:

Ensure the retaining claw is correctly positioned.

- Tighten the securing nut to 20 Nm.

- Once again, check the TDC marking at theflywheel.

- Tighten the new bolts for attaching the injec-tion pump sprocket to 20 Nm.

Note:

The bolts for attaching the sprocket must onlybe used once as these are stretch bolts.

- Tighten the bolt for attaching the camshaftsprocket to 45 Nm (counterhold with MP1-216).

- Remove the locking pin 3359.

- Remove the adjusting straightedge MP 1-312from the camshaft.

- Rotate the crankshaft two revolutions in di-rection of rotation of engine until the crank-shaft is again positioned at TDC of cylinder1.

- Check whether the injection pump sprocketcan be locked with locking pin 3359.

If it is not possible to lock the injection pumpsprocket:

- Rotate the crankshaft sufficiently until theholes for the locking pin are aligned and lockthe injection pump sprocket with locking pin3359.

- Slacken the bolts attaching the injectionpump sprocket.

- Rotate crankshaft until the help marking onthe flywheel is aligned with the edge of theadjusting device.

If it is possible to lock the injection pumpsprocket:

- Tighten the bolts attaching the injection pumpsprocket to 20 Nm + ¼ turn (90°).

- Remove locking pin 3359.


Edition 03.98

- Connect the injection lines, fuel feed line andelectric cables.

- Fill the injection pump with clean diesel fuelas follows:

- Screw the connection fitting V.A.G 1318/10 into the return flow opening of the in-jection pump.

- Connect the vacuum pump (e.g. V.A.G1390) to the return-flow opening with atransparent fuel line about 1 m long.

- Operate the vacuum pump until fuel flowsout of the return-flow opening. Do notdraw fuel into the vacuum pump.

- Close the return-flow pipe.

- Install top toothed belt guard, vacuum pumpand cylinder head cover.

- Install air guide pipe from intercooler withhose to the intake manifold.

- Install connectors at intake manifold pres-sure sender and intake manifold tempera-ture sender.

- Install right headlight ⇒ Electrical System;Repair Group 94; Exterior Lights/Bulbs/Switches.

- Install top engine trim panel.

- Install sound-absorbing pan and air guidepipe between intercooler and turbocharger.

- Dynamically test and set commencement ofinjection ⇒ page 23-13.

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Edition 03.98

- Slacken the third bolt attaching the injectionpump sprocket and turn the pump shaftslightly:

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 -2-for the hub otherwise the basic setting of theinjection pump will be altered and cannot be setwith workshop tools.

- Tighten the new bolts for attaching the injec-tion pump sprocket to 20 Nm + 1/4 turn (90°)(counterhold with locking pin 3359).

Note:

The bolts for attaching the sprocket must onlybe used once as these are stretch bolts.

- Install top toothed belt guard.

- Install air guide pipe from intercooler withhose to intake manifold.

- Plug in connectors at intake manifold pres-sure sender and intake manifold tempera-ture sender.

- Install top engine trim panel.

- Install right headlamp ⇒ Electrical System;Repair Group 94; Exterior Lights/Bulbs/Switches.

- Once again check commencement of injec-tion for specified value.

If the commencement of injection is not withinthe specified range:

- Correct the setting at the injection pumpsprocket.

If the commencement of injection is not withinthe specified range:

- Check fuel injection control ⇒ page 23-28,replace injection pump if necessary.

Injection pump is o.k.:

- Replace engine electronics control unit⇒ page 23-20.


Edition 05.97

Removing and installing and test-ing injectors

Note:

Faulty injectors cause the following problems:

♦ Loss of power

♦ Excessive black smoke in exhaust

♦ Intensified blue exhaust when starting fromcold

♦ High fuel consumption

♦ Engine overheats

♦ Knocking in one or several cylinders

♦ Misfiring

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.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 MP1-230 and auxiliary tool

Removing

- Use the ring wrench (e.g. 3035) to detachthe injection pipes.

- If necessary, unscrew banjo bolt for return-flow pipe (injector of cyl. 3).

Note:

Always remove all of the injection pipes. Do notalter the shape.

- Unscrew securing bolt, take off tensioningclamp and remove injector.

- Shop-make the following auxiliary tool forinjectors which are tight:

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Edition 05.97

- If the fault moves with the injector, replacethe relevant injector.

- If the fault remains at the cylinder, test thecompression.

- If the compression is o.k., replace the rel-evant delivery valve together with seal⇒ page 23-4, Servicing injection pump.

Notes:

♦ Always use a soft object (plastic, wood) toremove the seal from the pump otherwisethe 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 2stages.If there is any problem with these injectors, it isonly possible to replace them as it is neitherpossible to set the pressure nor to repair theinjector.

Important!

When testing injectors, ensure that the fuel spraydoes not strike your hands otherwise the fuel willpenetrate into the skin as a result of the high pres-sure and may cause severe injuries.

Pressure gauge switched on

- Slowly press the pump lever down. Whenfuel ejection starts, read off the ejection pres-sure. If the ejection pressure differs from thespecified pressure, replace the injector.

New injectors 19...20 MPa

Wear limit 17 MPa

Testing for leaks

Pressure gauge switched on

- Slowly press the pump lever down and main-tain the pressure at about 15 MPa for 10seconds. During this time, no fuel should dripout of the injector opening.

- If a leak exists, replace injector.

Test injectors with injector tester (e.g. V.A.G

1322) and pressure pipe V.A.G 1322/2.

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Edition 05.97

Testing start of injection con-trol

Testing injection timing controlrange



Procedure

- Initiate final control diagnosis and actuate thestart of injection valve ⇒ page 01-18.

Readout in display:

Actuation of the valve is indicated by a clearlyaudible change in the combustion noise (die-sel combustion noise).

- Initiate the basic setting ⇒ page 01-21.

Readout in display, e.g.:

- Set start of injection, if necessary⇒ page 23-13.

- Remove the fuse 34 -arrow-.


Start of injection valve -N108

Basic setting 0 →

42 46 0 20 90 201 64 153 127 83

Basic setting 0 →

42 255 0 20 90 201 64 153 127 83

- Observe the readout in display zone 2.

The readout should increase to 255

Note:

As a result of the interruption to the voltage, thestart of injection valve is closed. The pump in-ternal chamber pressure can no longer be low-ered and acts to its full extent on the piston ofthe injection control. The injection control ismoved toward the „advanced“ stop.

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Edition 03.98

Read measured value block 1 →

900 rpm 6.5 mg/H 1.480 V 87.3 °C


900 rpm 272 mg/H 268 mg/H 54 %


900 rpm 272 mg/H 268 mg/H 54 %

Testing exhaust gasrecirculation system

Testing exhaust gas recirculation

Operation of the exhaust gas recirculation sys-tem is tested by measuring the inducted airmass. If exhaust gas is recirculated, the freshair portion which is detected by the air massmeter is less. The greater the quantity of ex-haust gas recirculated, the smaller the signalsupplied by the air mass meter.



Procedure for models 07.97

- Read measured value block, display group001, engine idling ⇒

page 01-36.

Readout in display:

- Check readout in display block 4 (coolanttemperature).

Specification: at least 85 °C

Do not continue with the test until the coolanttemperature is reached.

- Press the key C.

- Press the key 0 twice and key 3 for „Displaygroup number 003“ and confirm the entry withthe key Q.

Readout in display:

- Briefly blip the throttle and then allow theengine to continue idling.

- Check the readout in display block 2 (speci-fied air mass).

Specification: 230...370 mg/H

If the air mass is higher than specified, the causemay be the following:

♦ Coolant temperature too low

♦ Intake manifold temperature very high

♦ Injected quantity too high


Edition 03.98


900 rpm 272 mg/H 268 mg/H 54 %


EGR valve -N18

♦ Fault in fault memory

- Check the readout in display block 3 (actualair mass).

Specification: should agree with specified airmass in display block 2(tolerance ± 20 mg/H)

If the actual air mass is more than 20 mg/H lowerthan the specified air mass, the following faultsare possible:

♦ Unmetered air in intake area

♦ Excessive exhaust gas recirculation

If the actual air mass is more than 20 mg/Hhigher than the specified air mass, the follow-ing 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:

- Start final control diagnosis and operate theEGR valve ⇒

page 01-18.

Readout in display:

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.:

- Test mechanical exhaust gas recirculationvalve:⇒1.9-ltr./66 kW Engine, Mechanical Compo-nents; Repair Group 26; Exhaust gasrecirculation system

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23 Fuel Formation/ Fuel Injection

Edition 02.99

If the specification is not achieved:

- Repeat the test and accelerate the vehicleat full throttle.

Models 07.97

Specification in display block 3:1800...2050 mbar (charge pressure)

Specification in display block 1:>750 mg/H (inducted air mass)

Models 08.97

Specification in display block 3:1700...2080 mbar (charge pressure)

Specification in display block 1:>800 mg/H (inducted air mass)

Continued for all models

If the specification is not achieved:

- 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/HModels 08.97 = 550 mg/H


Read measured value block 10→830 mg/H 1030 mbar 1850 mbar 100 %




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Edition 03.98


0 km/h 0 0 0 000000 0


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Testing brake light switch andbrake pedal switch

In view of the fact that the fuel injection systemoperates with an accelerator pedal sender(potentiometer), which could develop a fault, theengine is governed for safety reasons when thebrakes are applied. The control unit requires thebrake light switch signal and, in addition, thebrake pedal switch signal for this purpose. Whatthis means, therefore, is that, if the brake is op-erated when the accelerator pedal is constantlydepressed, the engine is immediately governeddown to idling speed. If the switch positions arenot clearly detected, this can result in uninten-tional governing of the engine speed.



Procedure

- Read measured value block, display group006, engine idling ⇒

page 01-33.

Readout in display:

- Check readout in display block 2.

Specification: 0 0 0

- Slowly depress brake.

Specification: 0 1 1Both readouts should jump from 0 to 1.

♦ Middle readout = brake pedal switch

♦ Right-hand readout = brake light switch

- Slowly release brake pedal into rest position.

Specification: 0 0 0Both readouts should switch back again from1 to 0.

If one of the readouts or both does not switchfrom 0 to 1:

- Test the switches or the cable connectionsto the switches.⇒Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

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Edition 03.98

Servicing intake manifold flap 08.97

The intake manifold flap is closed for about 3seconds when the engine is switched off andthen opens again. This reduces the engine stopjolt.

Testing intake manifold flap changeover ⇒ page23-57.

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 intakemanifold flap

10 - Intake manifold flap changeover valve-N239♦ Testing ⇒ page 23-57

11 - Vacuum supply♦ From vacuum pump

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Glow Plug System 28

Edition 03.98

Testing glow plug system

Testing operation


♦ Hand-held multimeter (e.g. V.A.G 1526)

♦ Current flow diagram

Test conditions

Battery voltage at least 11.5 V

Diesel direct injection system control unit(J248) o.k.

Strip fuse for glow plugs (S 132) o.k.

Test procedure


- Unplug connector -1- at the coolant tempera-ture sender (G62) -2-.

Note:

When the connector is unplugged from thesender, the „cold“ engine state is simulated andappropriate glow plug heating operation is car-ried out when the ignition is switched on.

- Unplug the glow plug connectors from theglow plugs.

- Connect the multimeter for voltage measure-ment to a glow plug connector and to engineearth.

- 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 shortcircuit.

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

During the simulated glow plug heating opera-tion, the glow period warning lamp (K29) shouldcome on.

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Documents

38613476 Workshop Manual Octavia Engine Fuel Injection 1 9tdi