Page 10 Passat (2.8L-Engine - Motronic Multiport Fuel Injection (MFI)/128kW), code AAA, from August 1994 Diagram Title Num/Page Passat (2.8L-Engine - Motronic Multiport Fuel Injection (MFI)/128kW), code AAA, from 02/01 August 1994 01/02 Battery, ignition/starter switch 01/03 Fresh air blower 03/01 Coolant fan, two speeds 02/02 Generator (GEN), starter, fuel pump (FP), fuel level sensor Ignition system, motronic engine control module (ECM), heated oxygen sensor (HO2S),...
Page 11 Passat (1.9L-Engine - Turbo Diesel Fuel Injection (DFI)/55kW), code AAZ, from August 1994 Diagram Title Num/Page Passat (1.9L-Engine - Turbo Diesel Fuel Injection (DFI)/55kW), code AAZ, from August 17/01 1994 01/02 Battery, ignition/starter switch 01/03 Fresh air blower 04/01 Coolant fan, two speeds, 250W, code AAZ, from August 1994 17/02 Generator (GEN), starter Automatic glow time control module, fuel cut-off valve, idle air control (IAC) solenoid,...
Page 12 Passat (2.0L-Engine - Motronic Multiport Fuel Injection (MFI)/85kW), code ABA, from February 1995 Diagram Title Num/Page Passat (2.0L-Engine - Motronic Multiport Fuel Injection (MFI)/85kW), code ABA, from 24/01 February 1995 01/02 Battery, ignition/starter switch 01/03 Fresh air blower 03/01 Coolant fan, two speeds 24/02 Generator (GEN), starter, fuel pump (FP), fuel level sensor Motronic engine control module (ECM), heated oxygen sensor (HO2S) relay, heated...
Page 13 Common Systems Diagram Title Num/Page 25/01 Airbag, from August to September 1994 18/01 Airbag, from October Air conditioning, 2.8L Engine-Motronic Multiport Fuel Injection (MFI)/128kW, code 06/01 AAA, from August 1994 Air conditioning, 2.0L Engine-Motronic Multiport Fuel Injection (MFI)/85kW, code ABA, 26/01 from February 1995 Air Conditioning, 1.9L Engine-Turbo Diesel Fuel Injection (DFI)/55kW, code AAZ, from...
Page 139: Battery, Ignition/Starter Switch
Passat (2.8L-Engine - Motronic Multiport Fuel Injection (MFI)/128kW), code AAA, from August 1995 Diagram Title Num/Page Passat (2.8L-Engine - Motronic Multiport Fuel Injection (MFI)/128kW), code AAA, from 31/01 August 1995 34/02 Battery, ignition/starter switch 34/03 Fresh air blower 03/01 Coolant fan, two speeds 31/02 Generator (GEN), starter, fuel pump (FP), fuel level sensor 31/03...
Page 140: Fresh Air Blower
Passat (2.0L-Engine - Motronic Multiport Fuel Injection (MFI)/85kW), code ABA, from August 1995 Diagram Title Num/Page Passat (2.0L-Engine - Motronic Multiport Fuel Injection (MFI)/85kW), code ABA, from 30/01 August 1995 34/02 Battery, ignition/starter switch 34/03 Fresh air blower 03/01 Coolant fan, two speeds 30/02 Generator (GEN), starter, fuel pump (FP), fuel level sensor Motronic engine control module (ECM), heated oxygen sensor (HO2S), heated oxygen...
Page 141: Instrument Cluster, Engine Coolant Level/Temperature (Ecl/Ect) Warning Light, Visual And
Passat (1.9L-Engine - Turbo Diesel Fuel Injection (DFI)/55kW), code 1Z, from August 1995 Diagram Title Num/Page Passat (1.9L-Engine - Turbo Diesel Fuel Injection (DFI)/55kW), code 1Z, from August 29/01 1995 34/02 Battery, ignition/starter switch 34/03 Fresh air blower 04/01 Coolant fan, two speeds 29/02 Generator (GEN), starter Diesel direct fuel injection (DFI) engine control module (ECM), engine speed (RPM)
Page 142 34/16 Windshield wiper/washer system Rear window wiper/washer system, ABS warning light, airbag malfunction indicator lamp 34/17 (MIL), brake and parking brake warning light...
Page 143: Air Conditioning, 1.9L Engine-Turbo Diesel Fuel Injection (Dfi)/55Kw, Code Aaz, From
Common Systems Diagram Title Num/Page 18/01 Airbag, from October 1994 Air conditioning, 2.8L Engine-Motronic Multiport Fuel Injection (MFI)/128kW, code 06/01 AAA, from August 1994 Air conditioning, 2.0L Engine-Motronic Multiport Fuel Injection (MFI)/85kW, code ABA, 26/01 from February 1995 Air Conditioning, 1.9L Engine-Turbo Diesel Fuel Injection (DFI)/55kW, code AAZ, from 05/01 August 1994 Air Conditioning, 1.9L Engine-Turbo Diesel Fuel Injection (DFI)/66kW, code 1Z, from...
Page 268 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA m.y. 1995 00 - General, Technical data Technical data Engine numbers, location Engine technical data 10 - Engine - Assembly Engine, removing and installing Removing Installing Tightening torques Engine and transmission, aligning Rubber bushings for engine mount, replacing Vehicles with A/C, additional information on removing and installing 13 - Engine - Crankshaft, Cylinder block...
Page 269 Valve guides, removing and replacing Valve stem seals, replacing 17 - Engine - Lubrication Lubrication system, general information Lubrication system, components Oil pressure and oil pressure switches, checking 19 - Engine - Cooling system Cooling system General information Cooling system components, body side Cooling system components, engine side Coolant pump, disassembling and assembling Cooling system, draining and filling...
Page 270 Secondary Air Injection (AIR) system Function Secondary Air Injection (AIR) system components, removing and installing Combi-valve and check valve, checking Secondary Air Injection (AIR) pump motor, checking Secondary Air Injection (AIR) solenoid valve, checking...
Page 271 Technical data Page 1 of 2 00-1 Technical data Engine numbers, location The engine numbers ("engine code" and "serial number") are die-stamped in the front of the cylinder block above the crankcase breather. In addition, there is a label with the "engine code"...
Page 272 Technical data Page 2 of 2 00-2 Engine technical data Engine code Manufactured from: 03.95 08.95 07.95 Displacement liters Output kW at RPM 85 at 5400 85 at 5400 HP at RPM 115 at 5400 115 at 5400 Torque Nm at RPM 165 at 3200 165 at 3200 Ft.
Page 273 Engine, removing and installing Page 1 of 16 10-1 Engine, removing and installing Special tools, testers and auxiliary items Engine sling 2024 A G 000 100 grease Torque wrench VAG 1331: 5-50 Nm (4- 37 ft lb) Torque wrench VAG 1332: 40-200 Nm (30-148 ft lb) Cable ties http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 274 Engine, removing and installing Page 2 of 16 10-2 Removing The engine is removed by moving it toward the front together with the transmission. CAUTION! Determine correct radio anti-theft coding before disconnecting the battery. Ignition switched off. - Disconnect battery negative cable (ground strap).
Page 275 Engine, removing and installing Page 3 of 16 10-3 - Remove lock carrier (upper radiator support) with attached parts. Repair Manual Body Exterior, Interior, Repair Group 50 - Remove coolant fan and fan shroud. Vehicles with A/C: - Refer to additional information and removal instructions Page 10-14 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 276 Engine, removing and installing Page 4 of 16 10-4 Vehicles with manual transmission: - Remove clutch slave cylinder. Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 - Disconnect gear shift mechanism from transmission. Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 34 - Install engine sling 2024 A and lift slightly with shop crane:...
Page 277 Engine, removing and installing Page 5 of 16 10-5 Vehicles with automatic transmission - Install engine sling 2024 A and lift slightly with shop crane: Drive belt side: 4th hole up from hook in cross bar position -1- Flywheel side: 2nd hole up from hook in cross bar position -6- CAUTION!
Page 278 Engine, removing and installing Page 6 of 16 10-6 All vehicles: - Disconnect subframe and, on one side, pry bracket from rubber subframe mounting. - Separate power steering pressure lines from disconnected subframe. - Lift engine together with transmission out toward the front. CAUTION! Lift unit out carefully to avoid damage to body.
Page 279 Engine, removing and installing Page 7 of 16 10-7 Installing Install in reverse order of removal, but note the following: - Check clutch release bearing for wear, replace if necessary. - Lightly lubricate clutch release bearing, clutch release guide sleeve and transmission input shaft splines with G 000 100 grease.
Page 280 Engine, removing and installing Page 8 of 16 Steering, Repair Group 48. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 281 Engine, removing and installing Page 9 of 16 10-8 - Install lock carrier with attached parts. Repair Manual Body Exterior, Interior, Repair Group 50 Engines with ribbed drive belt without tensioner: - Install ribbed drive belt Page 13-11 All engines: - Fill engine cooling system coolant Page 19-9...
Page 282 Engine, removing and installing Page 10 of 16 - Carry out idle check. Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 24 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y.
Page 283 Engine, removing and installing Page 11 of 16 10-9 Tightening torques Fastener/Connection Tightening torque Engine to M10 60 Nm (44 ft lb) transmission M12 80 Nm (59 ft lb) Flywheel cover plate M7 10 Nm (07 ft lb) Axle shafts to drive flanges 45 Nm (33 ft lb) Exhaust pipe to manifold 40 Nm (30 ft lb)
Page 284 Engine, removing and installing Page 12 of 16 10-10 Engine and transmission mount tightening torques Bolt threads lubricated Front engine mount A - 55 Nm (41 ft lb) B - 55 Nm (41 ft lb) C - 50 Nm (37 ft lb) Rear right engine mount A - 25 Nm (18 ft lb) B - 50 Nm (37 ft lb)
Page 285 Engine, removing and installing Page 13 of 16 10-11 Rear left engine mount for manual transmission A - 60 Nm (44 ft lb) B - 25 Nm (18 ft lb) C - 30 Nm (22 ft lb) Rear left engine mount for automatic transmission A - 60 Nm (44 ft lb) B - 25 Nm (18 ft lb)
Page 286 Engine, removing and installing Page 14 of 16 10-12 Engine and transmission, aligning Aligning is only necessary when the engine and transmission have been removed and additionally the sub-frame and engine carrier bonded rubber mounts have been loosened. - Loosen bonded rubber mount -A- (engine mount) on sub-frame and console.
Page 287 Engine, removing and installing Page 15 of 16 10-13 Rubber bushings for engine mount, replacing - Install engine holding fixture 10-222A with supports 10-222A/1. - Connect engine sling in hook eye on cylinder head (left side) and tighten to lift engine slightly. - Remove engine mount.
Page 288 Engine, removing and installing Page 16 of 16 10-14 Vehicles with A/C, additional information on removing and installing CAUTION! DO NOT open A/C refrigerant circuit. DO NOT release A/C refrigerant into the atmosphere. Refrigerant lines bend easily. Only trained technicians using the proper equipment should replace the A/C refrigerant.
Page 289 Engine disassembling and assembling Page 1 of 23 13-1 Engine disassembling assembling CAUTION! If large amounts of metal shavings or small metal particles are found in the engine oil, caused by wear of the crankshaft main and connecting rod bearings, thoroughly clean the oil passages to remove...
Page 290 Engine disassembling and assembling Page 2 of 23 13-2 Part I 1 - Tensioner 2 - 25 Nm (18 ft lb) 3 - Tensioner lever 4 - Dust sleeve 5 - 10 Nm (7 ft 6 - Drive belt guard, lower 7 - Drive belt guard,...
Page 291 Engine disassembling and assembling Page 3 of 23 13-3 11 - Drive belt guard 12 - Drive belt guard, rear Drive belt sprocket, intermediate shaft 14 - 80 Nm (59 ft lb) loosen tighten holding fixture 3036 15 - Drive belt sprocket, crankshaft 16 - 90 Nm (66...
Page 292 Engine disassembling and assembling Page 4 of 23 shoulder Turning additional -turn (90 ) can be done in stages 17 - Pulley coolant pump Version with ribbed belt http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 293 Engine disassembling and assembling Page 5 of 23 13-4 18 - Ribbed drive belt Before removing, mark direction rotation Removing installing Page 13-11 19 - Vibration damper, crankshaft Also serves as pulley for ribbed drive belt Assembly only possible in one position (holes offset)
Page 294 Engine disassembling and assembling Page 6 of 23 Steering, Repair Group 48 21 - Pulley coolant pump Version for V-belt 22 - Pulley crankshaft http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 295 Engine disassembling and assembling Page 7 of 23 13-5 Part II 1 - Positive Crankcase Ventilation (PCV) valve 2 - 20 Nm (15 ft lb) 3 - Intake manifold, upper 4 - Gasket Always replace 5 - Cap Replace gasket if damaged 6 - 10 Nm (7 ft 7 - Reinforcing...
Page 296 Engine disassembling and assembling Page 8 of 23 13-6 11 - Cylinder head cover gasket Replace damaged 12 - Cylinder head Removing installing Page 15-6 When replaced, always replace engine coolant 13 - Cylinder head gasket Always replace Always replace engine coolant 14 - Lifting eye...
Page 297 Engine disassembling and assembling Page 9 of 23 16 - Grommet 17 - Hose connection From crankcase breather Page 13-8 item 13 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 298 Engine disassembling and assembling Page 10 of 23 13-7 Part III 1 - Cylinder block Removing installing sealing flange flywheel or drive plate Page 13- Removing installing crankshaft Page 13-27 Disassembling assembling pistons and connecting rods Page 13-31 2 - Woodruff Check for tight fit 3 - O-ring...
Page 299 Engine disassembling and assembling Page 11 of 23 6 - Knock sensor Checking Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 01 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y.
Page 300 Engine disassembling and assembling Page 12 of 23 13-8 7 - 20 Nm (15 ft lb) Incorrect tightening torque influence knock sensor function 8 - Ignition distributor Installing Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y.
Page 301 Engine disassembling and assembling Page 13 of 23 14 - Oil cooler Coat flange contact area, outside sealing ring, with sealer AMV 188 100 02 Ensure clearance to surrounding components Replace if oil has been contaminated Caution!, Page 13-1 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 302 Engine disassembling and assembling Page 14 of 23 13-9 15 - Oil filter Loosen with strap wrench Tighten by hand Follow installation instructions on oil filter 16 - 10 Nm (7.5 ft lb) 17 - Engine speed (RPM) sensor Checking Repair Manual, 2.0 Liter 4-Cyl.
Page 303 Engine disassembling and assembling Page 15 of 23 (90 ) Always replace 20 - 30 Nm (22 ft lb) 21 - Tensioner 22 - Bracket 23 - Seal Always replace http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 304 Engine disassembling and assembling Page 16 of 23 13-10 24 - Tensioner lever 25 - Hammer- head screw 26 - Coolant pump Disassembling assembling Page 19-7 27 - Oil pan 28 - 20 Nm (15 ft lb) Loosen or tighten bolts on flywheel side...
Page 305 Engine disassembling and assembling Page 17 of 23 13-11 Ribbed drive belt, removing and installing Note: Before removing the ribbed belt, mark its running direction so that it can be reinstalled the same way. When installing, be sure belt is correctly seated in pulleys.
Page 306 Engine disassembling and assembling Page 18 of 23 13-12 Installing - Install ribbed belt on crankshaft vibration damper. - Install V-belt for power steering pump. Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 48 Vehicles without A/C: - Lift belt tensioner with ribbed belt installation tool 3299 and install ribbed belt.
Page 307 Engine disassembling and assembling Page 19 of 23 13-13 Toothed drive belt, removing and installing (Adjusting valve timing) See Caution! and notes Page 13-14 Special tools, testers and auxiliary items Ribbed belt installation tool 3299 Pin wrench Matra V159 Torque wrench VAG 1331 (5-50 Nm) Removing - Remove ribbed drive belt Page 13-11...
Page 308 Engine disassembling and assembling Page 20 of 23 13-14 Installing Note: For repairs that require the toothed belt to be removed, carry out the toothed belt adjustment as follows. - Align marking on camshaft sprocket with marking on drive belt guard. CAUTION! Before turning the camshaft, make sure that the pistons are NOT at Top...
Page 309 Engine disassembling and assembling Page 21 of 23 13-15 Engine installed: - Align flywheel -A- or drive plate -B- marks as shown (arrows) to set crankshaft to Cyl. 1 TDC. Engine removed: - Turn crankshaft vibration damper to align notch with timing mark (arrow) and set crankshaft to Cyl.
Page 310 Engine disassembling and assembling Page 22 of 23 13-16 - Turn intermediate shaft drive belt sprocket with toothed belt (in direction indicated by arrows) until distributor rotor aligns with Cyl. 1 marking on distributor housing. Drive belt slips over teeth of crankshaft drive belt sprocket.
Page 311 Engine disassembling and assembling Page 23 of 23 13-17 - Increase tension on toothed belt by turning tensioner pulley with pin wrench (e.g. Matra V159) in direction of arrow. It must be just possible to twist the belt by 90 with the thumb and forefinger half-way between the camshaft and intermediate shaft sprockets.
Page 312 Sealing flange and flywheel or drive plate, removing and installing Page 1 of 11 13-18 Sealing flange and flywheel or drive plate, removing installing Note: For clutch repairs Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 1 - Oil seal Install with 10- Lightly...
Page 313 Sealing flange and flywheel or drive plate, removing and installing Page 2 of 11 5 - Gasket Always replace 6 - Cylinder block Removing installing crankshaft Page 13-27 Disassembling assembling pistons and connecting rods Page 13-31 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 314 Sealing flange and flywheel or drive plate, removing and installing Page 3 of 11 13-19 7 - 60 Nm (44 ft lb) plus additional -turn (90 ) Always replace 8 - Flywheel or drive plate Drive plate, removing installing Page 13-24 remove install...
Page 315 Sealing flange and flywheel or drive plate, removing and installing Page 4 of 11 with oil seal Replace only as complete assembly Lightly lubricate sealing 12 - Oil seal Replacing Page 13-21 Intermediate shaft First remove ignition distributor Axial clearance max.
Page 316 Sealing flange and flywheel or drive plate, removing and installing Page 5 of 11 13-20 14 - O-ring Replace damaged Intermediate shaft sealing flange http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 317 Sealing flange and flywheel or drive plate, removing and installing Page 6 of 11 13-21 Crankshaft oil seal (pulley end), replacing Special tools, testers and auxiliary items Counter-hold tool 3099 Oil seal extractor 2085 Oil seal fitting tool 3083 Removing - Remove ribbed drive belt Page 13-11 - Remove toothed camshaft drive belt...
Page 318 Sealing flange and flywheel or drive plate, removing and installing Page 7 of 11 13-22 - Lubricate threaded head of seal puller 2085, place in position and screw into seal as far as possible by applying pressure in direction of arrow.
Page 319 Sealing flange and flywheel or drive plate, removing and installing Page 8 of 11 13-23 - Press seal in to stop with 3083. - Install drive belt and adjust tension Page 13-13 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 320 Sealing flange and flywheel or drive plate, removing and installing Page 9 of 11 13-24 Drive plate, removing and installing Special tools, testers and auxiliary items Holding tool VW 558 M8x45 hex bolt and two M10 hex nuts Depth gauge Loosening and tightening drive plate - Fasten holding tool VW 558 to driveplate with hex bolt M8x45.
Page 321 Sealing flange and flywheel or drive plate, removing and installing Page 10 of 11 13-25 Installing - Install driveplate using washer with cut-outs -1-. - Install new bolts -3- and tighten to 30 Nm (22 ft lb). - Check clearance between drive plate and cylinder block at three points and calculate average value.
Page 322 Sealing flange and flywheel or drive plate, removing and installing Page 11 of 11 13-26 If clearance dimension is NOT as specified: - Remove drive plate and install shim - - Install and tighten bolts -3- in three stages. Stage I: 30 Nm (22 ft lb) Stage II: 60 Nm (44 ft lb) Stage III: additional -turn (90 )
Page 323 Crankshaft, removing and installing Page 1 of 6 13-27 Crankshaft, removing installing 1 - Main bearing shells 1, 2, 4 and 5 Without groove: for main bearing caps 1, 2 and 5 With oil groove: for main bearing cap 4 and cylinder block Do not...
Page 324 Crankshaft, removing and installing Page 2 of 6 only, NOT additional turn (90 ) 3 - Main bearing caps Main bearing cap 1: pulley Main bearing cap 3 has recesses for thrust washers - Holding tabs on bearing shells in cylinder block and main...
Page 325 Crankshaft, removing and installing Page 3 of 6 13-28 4 - Main bearing shell 3 Without groove: for main bearing With oil groove: cylinder block 5 - Thrust washer For main bearing cap 3 Note installation position 6 - Sensor gear For RPM sensor...
Page 326 Crankshaft, removing and installing Page 4 of 6 13-29 8 - Crankshaft Dimensions Page 13-30 Axial clearance: New: 0.07-0.17 (0.0028- 0.0067 in.) Wear limit: 0.25 mm (0.00984 in.) Radial clearance: Measure Plastigage New: 0.02-0.06 (0.0008- 0.0024 in.) Wear limit: 0.17 mm (0.0067 in.) CAUTION!
Page 327 Crankshaft, removing and installing Page 5 of 6 washer cylinder block bearing 3 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 328 Crankshaft, removing and installing Page 6 of 6 13-30 Crankshaft dimensions Reconditioning dimension Crankshaft journal Connecting rod journal diameter - mm (in.) diameter - mm (in.) maximum -0.022 (0.00087) -0.022 (0.00087) Basic dimension (nominal) -54.00 (2.1260) -47.80 (1.8819) minimum -0.042 (0.00165) -0.042 (0.00165) maximum -0.022 (0.00087)
Page 329 Pistons and connecting rods, disassembling and assembling Page 1 of 12 13-31 Pistons and connecting rods, disassembling assembling 1 - Piston ring Offset gaps by Remove and install with piston ring pliers "TOP" marking faces toward piston crown Checking ring Fig.
Page 330 Pistons and connecting rods, disassembling and assembling Page 2 of 12 compressor Dimensions Fig. 4 3 - Connecting rod With oil supply hole for piston pin lubrication Replace only as complete Installation position: marking -A- points toward pulley end Make matching marks -B- for cylinder...
Page 331 Pistons and connecting rods, disassembling and assembling Page 3 of 12 13-32 4 - Connecting bearing Note installation position 5 - 30 Nm (22 ft lb) plus additional -turn (90 ) threads contact surface Measuring radial clearance: tighten to 30 Nm (22 ft lb) only, additional -turn...
Page 332 Pistons and connecting rods, disassembling and assembling Page 4 of 12 Opening pressure: 2.5-3.2 bar (36- 46 psi) applicable from 04.95 7 - Oil spray piston cooling applicable from 04.95 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 333 Pistons and connecting rods, disassembling and assembling Page 5 of 12 13-33 8 - Bearing shell Note installation position Shells with oil hole installed in connecting rod - 3 -, face toward piston pin Do not interchange worn bearing shells Check to make sure...
Page 334 Pistons and connecting rods, disassembling and assembling Page 6 of 12 with Plastigage New: 0.01-0.06 (0.0004- 0.0024) Wear limit: 0.12 mm (0.0047) CAUTION! DO NOT turn crankshaft while measuring radial clearance. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 335 Pistons and connecting rods, disassembling and assembling Page 7 of 12 13-34 9 - Cylinder block Checking cylinder bore diameter Fig. 5 Piston and cylinder dimensions Page 13-39 10 - Connecting rod bolt 11 - Circlip 12 - Piston pin If difficult remove, warm...
Page 336 Pistons and connecting rods, disassembling and assembling Page 8 of 12 13-35 Special tools, testers and auxiliary items Feeler gauges Internal dial gauge 50-100 mm Micrometer 75-100 mm Fig. 1 Checking piston ring gap - Squarely insert piston ring into cylinder from above, to approx.
Page 337 Pistons and connecting rods, disassembling and assembling Page 9 of 12 13-36 Fig. 2 Checking piston ring/groove clearance - Clean ring groove before measuring. Piston ring Side clearance - mm (in.) Wear limit Compression 0.02-0.05 0.15 ring (0.0008- (0.0059) 0.0020) Oil scraper 0.02-0.05 0.15...
Page 338 Pistons and connecting rods, disassembling and assembling Page 10 of 12 13-37 Fig. 4 Piston dimensions Engine code up to from 04.95 04.95 Dimension - 19.1 20.1 (in.) (0.752) (0.791) Dimension - (in.) (0.279) (0.279) Recess 66.5 65.0 diameter -c- (in.) (2.618) (2.559)
Page 339 Pistons and connecting rods, disassembling and assembling Page 11 of 12 13-38 Fig. 5 Cylinder bore, checking - Use 50-100 mm internal micrometer. - Measure in direction -A- perpendicular to crankshaft, and direction -B- parallel to crankshaft. - Measure in three places as shown. 1 - 10 mm (0.39 in.) from top 2 - Center 3 - 10 mm (0.39 in.) from bottom...
Page 340 Pistons and connecting rods, disassembling and assembling Page 12 of 12 13-39 Piston and cylinder dimensions Piston and cylinder dimensions up to04.95 Reconditioning Piston Cylinder dimension diameter bore mm (in.) diameter - mm (in.) Basic dimension 82.485 82.51 (3.24744) (3.2484) 1st oversize 82.735 82.76...
Page 341 Cylinder head removal and installation Page 1 of 9 15-1 Cylinder head removal installation Checking compression pressures Page 15-8 Note: When installing a reconditioned cylinder head, oil the contact surfaces between valve lifters and cam lobes after installing the head. Remove plastic washers that...
Page 342 Cylinder head removal and installation Page 2 of 9 15-2 1 - Positive Crankcase Ventilation (PCV) valve 2 - Grommet 3 - 20 Nm (15 ft lb) 4 - Intake manifold, upper 5 - Gasket Always replace 6 - Cap Replace gasket if damaged...
Page 343 Cylinder head removal and installation Page 3 of 9 15-3 11 - Cylinder head bolt Always replace Loosening tightening sequence Page 15-6 12 - Gasket Always replace 13 - Cylinder head Installing Page 15-6 Check distortion Fig. 1 When replacing, always replace engine...
Page 344 Cylinder head removal and installation Page 4 of 9 15 - Camshaft sprocket Note position when installing drive belt Page 13-13 16 - Hook eye http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 345: Table Of Contents
Cylinder head removal and installation Page 5 of 9 15-4 17 - Drive belt guard, rear 18 - Toothed drive belt Check for wear Do not kink Removing installing Page 13-13 19 - Belt tensioner 20 - 45 Nm (33 ft lb) 21 - Drive belt guard,...
Page 346 Cylinder head removal and installation Page 6 of 9 15-5 Fig. 1 Checking cylinder head for distortion Max. permissible distortion: 0.1 mm (0.004 in.) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 347 Cylinder head removal and installation Page 7 of 9 15-6 Cylinder head, installing Special tools, testers and auxiliary items Torque wrench VAG 1332 (40-200 Guide pin 3070 Requirements Engine cold Pistons NOT at Top Dead Center (TDC) Installing - To align cylinder head, install guide pins from tool 3070 into holes for cylinder head bolts 8 and 10 (arrows).
Page 348 Cylinder head removal and installation Page 8 of 9 15-7 - Tighten cylinder head bolts in sequence shown, following same sequence for each of four stages. Note: To loosen cylinder head bolts, follow the same sequence in reverse order. - First tighten with torque wrench. Stage I 40 Nm (30 ft lb) Stage II...
Page 349 Cylinder head removal and installation Page 9 of 9 15-8 Compression pressure, checking Special tools, testers and auxiliary items Compression tester US 1120 Test conditions Engine oil temperature min. 30 C (86 F) - Disconnect harness connector for engine speed (RPM) sensor G28.
Page 350 Cylinder head, disassembling and assembling Page 1 of 24 15-9 Cylinder head, disassembling assembling Note: Cylinder heads with cracks between the valve seats or between a valve seat and the spark plug threads can be used without decreasing the service life.
Page 351 Cylinder head, disassembling and assembling Page 2 of 24 15-10 3 - Camshaft Axial play, checking Fig. 1 Removing installing Page 15-22 Check radial clearance with Plastigage Wear limit: 0.1 (0.004 in.) Runout: max. 0.01 mm (0.0004 in.) Identification and valve timing specifications Fig.
Page 352 Cylinder head, disassembling and assembling Page 3 of 24 Check for tight 5 - 80 Nm (60 ft lb) holding tool 3036 to loosen tighten 6 - Cylinder head Replacement cylinder heads with camshaft bearing shells Fig. See Note Page 15-9 Valve seats,...
Page 353 Cylinder head, disassembling and assembling Page 4 of 24 15-11 8 - Cylinder head refacing dimension Minimum height -a- = 132.6 (5.220 in.) 9 - Valves DO NOT reface by cutting or grinding, only hand- lapping is permitted Valve dimensions Fig.
Page 354 Cylinder head, disassembling and assembling Page 5 of 24 install with 3047A 12 - Valve spring Removing installing with cylinder head removed: use valve spring compressor 2037 Removing installing with cylinder head installed Page 15-29 13 - Valve spring seat, upper http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 355 Cylinder head, disassembling and assembling Page 6 of 24 15-12 14 - Valve keepers 15 - Hydraulic valve lifters Do not interchange Checking Page 15-25 When removed, store with camshaft contact surface pointing downward Before installing check camshaft axial play Fig.
Page 356 Cylinder head, disassembling and assembling Page 7 of 24 15-13 Special tools, testers and auxiliary items Dial indicator Holder VW 387 Fig. 1 Checking camshaft axial play Measure with valve lifters removed, and first and last bearing caps installed Wear limit: max. 0.15 mm (0.0059 in.) Fig.
Page 357 Cylinder head, disassembling and assembling Page 8 of 24 15-14 Fig. 3 Camshaft for reconditioned cylinder head with camshaft bearing shells Reconditioned cylinder heads or replacement engines are sometimes supplied with camshaft bearing shells. Standard camshaft: Dimension -a- = 26.00 mm (1.024 in.) Undersize camshaft: Dimension -a- = 25.75 mm (1.014...
Page 358 Cylinder head, disassembling and assembling Page 9 of 24 15-15 Fig. 4 Valve dimensions CAUTION! DO NOT recondition valves by cutting or grinding; only lapping is permitted. Dimension Intake Exhaust valve valve Head diameter 39.5 32.9 a - mm 0.15 0.15 Stem diameter 6.92...
Page 359 Cylinder head, disassembling and assembling Page 10 of 24 15-16 Fig. 5 Camshaft identification and valve timing Identification Cam lobe base circle: -a- = 34 mm Identification number and letter markings are stamped between intake and exhaust cam lobes for cylinders 1 and 3.
Page 360 Cylinder head, disassembling and assembling Page 11 of 24 15-17 Valve seats, refacing CAUTION! When refacing valve seats, remove only enough material to produce the correct seat contact pattern. The maximum permissible refacing dimension for the cylinder head must be calculated before refacing. If the maximum permissible head refacing dimension is exceeded, the hydraulic lifters will not function properly and the cylinder...
Page 361 Cylinder head, disassembling and assembling Page 12 of 24 15-18 The measured distance minus the specified minimum dimension is the maximum permissible refacing dimension, the maximum amount of material that can be removed when refacing the valve seats. Minimum cylinder head dimensions For intake valves: 33.8 mm (1.331 in.) For exhaust valves: 34.1 mm (1.343 in.) Example:...
Page 362 Cylinder head, disassembling and assembling Page 13 of 24 15-19 Intake valve seat refacing dimensions a - 39.2 mm (1.543 in.) b - maximum permissible refacing dimension c - approx. 2.0 mm (0.079 in.) Z - cylinder head lower edge 45 = valve seat angle 30 = valve seat upper correction angle...
Page 363: Toothed Drive Belt
Cylinder head, disassembling and assembling Page 14 of 24 15-20 Camshaft oil seal, removing and installing Special tools, testers and auxiliary items Holder tool 3036 Oil seal extractor 2085 Oil seal installation tool 10-203 Removing - Remove upper drive belt guard. - Loosen camshaft sprocket (hold with 3036).
Page 364: Installing
Cylinder head, disassembling and assembling Page 15 of 24 15-21 - Turn inner part of seal puller 2085 out two turns (approx. 3 mm) from the outer part and lock with knurled screw. - Lubricate threaded part of seal puller, install and, while applying pressure, screw into seal as far as possible.
Page 365 Cylinder head, disassembling and assembling Page 16 of 24 15-22 Camshaft, removing and installing Special tools, testers and auxiliary items Holder tool 3036 Torque wrench VAG 1331 (5-50 Torque wrench VAG 1576 (75-400 Removing - Remove upper drive belt guard. - Loosen camshaft sprocket (hold with 3036).
Page 366 Cylinder head, disassembling and assembling Page 17 of 24 15-23 - Remove camshaft bearing caps 1, 3 and 5. - Gradually loosen camshaft bearing caps 2 and 4, alternating in diagonal pattern to loosen nuts evenly. - Remove camshaft bearing caps 2 and 4. - Remove camshaft.
Page 367 Cylinder head, disassembling and assembling Page 18 of 24 15-24 - Insert Woodruff key in camshaft. - Install camshaft drive belt sprocket. Use holding tool 3036 Tightening torque: 80 Nm (59 ft lb) - Install toothed drive belt and adjust tension Page 13-13 CAUTION! After installing new hydraulic valve lifters, DO...
Page 368 Cylinder head, disassembling and assembling Page 19 of 24 15-25 Hydraulic valve lifters, checking Special tools, testers and auxiliary items Feeler gauges Wood or plastic wedge Note: Replace hydraulic valve lifters only as complete units (they can not be adjusted or repaired). Some irregular valvetrain noise during start up is normal.
Page 369 Cylinder head, disassembling and assembling Page 20 of 24 15-26 If there is less than 0.1 mm (0.004 in.) play, or no play, check as follows: - Press down with suitable non- marring tool (e.g. wood or plastic). If the lifter can be pushed down more than 0.1 mm (0.004 in.) before valve starts to open: - Replace valve lifter.
Page 370 Cylinder head, disassembling and assembling Page 21 of 24 15-27 Valve guide wear, checking Special tools, testers and auxiliary items Dial indicator Holder VW 387 New intake and exhaust valves (2) Checking - Place new valve in guide. Valve stem end must be flush with guide CAUTION! Intake guides and exhaust guides have different diameters.
Page 371 Cylinder head, disassembling and assembling Page 22 of 24 15-28 Valve guides, removing and replacing Special tools, testers and auxiliary items Drift 3121 7 mm reamer 3120 and cutting fluid Replacing - Clean and check cylinder head. Cylinder heads with valve seats that can no longer be refaced, or which have already been machined to the minimum dimension, should not have the valve guides replaced.
Page 372 Cylinder head, disassembling and assembling Page 23 of 24 15-29 Valve stem seals, replacing With cylinder head installed Special tools, testers and auxiliary items Slide hammer 3047A Adjustable rod 2036 Pressure hose VW 653/3 Valve spring compressor VW 541/1A with VW 541/5 Seal driver 3129 Replacing...
Page 373 Cylinder head, disassembling and assembling Page 24 of 24 15-30 - Install 2036 and adjust bar to cylinder stud height. - Install pressure hose VW 653/3 in spark plug hole and apply steady pressure. At least 6 bar (87 psi) - Compress valve springs with VW 541/1A and VW 541/5, and remove.
Page 374 Lubrication system, general information Page 1 of 12 17-1 Lubrication system, general information CAUTION! If large amounts of metal shavings or small metal particles are found in the engine oil, caused by wear of crankshaft and connecting rod bearings, thoroughly clean the oil passages to remove contaminants and help prevent later damage.
Page 375 Lubrication system, general information Page 2 of 12 17-2 Lubrication system, components 1 - Gasket Replace damaged 2 - Cap 3 - Oil dipstick The oil level must not be above the max. mark! Oil above shaded zone: DO NOT top up with engine oil!
Page 376 Lubrication system, general information Page 3 of 12 4 - Dipstick tube Pull out when draining 5 - 0.3 bar oil pressure switch - F22- 25 Nm (18 ft lb) Wire color: Blue/black Checking Page 17-7 leaking, cut seal replace. Engines up to 04.95...
Page 377: Ft Lb)
Lubrication system, general information Page 4 of 12 17-3 6 - Oil pressure switch - 1.8 bar (26 psi) 25 Nm (18 ft lb) Color: White Wire color: Yellow Checking Page 17-7 leaking, cut seal replace. 7 - Check valve 5 Nm (44 in lb) 8 - Plug...
Page 378 Lubrication system, general information Page 5 of 12 contact surfaces with AMV 188 100 (outside seal) Ensure clearance to surrounding components Caution! Page 17-1 13 - 25 Nm (18 ft lb) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 379: Opening Pressure
Lubrication system, general information Page 6 of 12 17-4 14 - Oil filter Loosen with filter wrench Tighten by hand Note installation instructions on oil filter 15 - Oil pump gears Gear backlash, checking Fig. 1 Checking axial clearance Fig. 2 16 - Oil pump cover with pressure...
Page 380 Lubrication system, general information Page 7 of 12 19 - Oil drain plug 30 Nm (22 ft lb) Replace if leaking. See Parts Catalog for correct application. In some cases, seal and drain plug are combined; do not interchange with separate seal and drain plug.
Page 381: Not Applicable From
Lubrication system, general information Page 8 of 12 17-5 21 - Oil pan Clean mating surface before assembly 22 - Suction line Clean screen if dirty 23 - Baffle plate remove, remove oil pump cover or suction line 24 - Gasket Always replace Baffle...
Page 382 Lubrication system, general information Page 9 of 12 from 04.95 26 - Oil spray nozzle piston cooling applicable from 04.95 27 - Gasket Always replace http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 383 Lubrication system, general information Page 10 of 12 17-6 Fig. 1 Checking oil pump backlash New: 0.05 mm (0.002 in.) Wear limit: 0.20 mm (0.008 in.) Fig. 2 Checking oil pump axial clearance Wear limit: 0.15 mm (0.006 in.) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 384 Lubrication system, general information Page 11 of 12 17-7 Oil pressure and oil pressure switches, checking For functional testing and repair of the optical (warning light) and acoustic (warning buzzer) oil pressure warning systems: Electrical Wiring Diagrams, Troubleshooting & Component Locations Special tools, testers and auxiliary items...
Page 385 Lubrication system, general information Page 12 of 12 17-8 - Connect VAG 1527B voltage tester between battery positive (B+) and 0.3 bar oil pressure switch -A-, using adapter cables from VW 1594 connector test kit. LED must light up - Start engine and increase RPM slowly. The LED must go out: Engines up to 04.95: 0.15-0.45 bar (2.1-6.5 psi)
Page 386 Cooling system Page 1 of 20 19-1 Cooling system General information WARNING! When the engine is hot, the cooling system is under pressure. If it is necessary to open the cooling system, do so slowly to relieve pressure gradually before starting repairs. Note: Hose connections are secured with spring-type or screw-type clamps.
Page 387 Cooling system Page 2 of 20 19-2 Cooling system components, body side 1 - Mounting 2 - 10 Nm (7 ft 3 - Radiator Removing installing Page 19-12 After replacing, always replace coolant 4 - Coolant hose, upper connector pipe Page 19- , item 1 5 - Coolant...
Page 388 Cooling system Page 3 of 20 Only with optional equipment 7 - Guide ring Note installation position Attached to fan shroud - 10 - with clips http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 389: Item
Cooling system Page 4 of 20 19-3 8 - Coolant fan -V7- Removing installing Page 19-12 9 - Auxiliary Only with optional equipment Removing installing Page 19-12 10 - Fan shroud Note installation position 11 - Connector 12 - Cover 13 - Expansion tank 14 - To coolant...
Page 390 Cooling system Page 5 of 20 transmission http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 391 Cooling system Page 6 of 20 19-4 16 - To cylinder head Page 19-5 item 8 17 - To upper coolant hose Page 19-5 item 2 18 - Cap Check with VAG 1274 and 1274/4 Test pressure: 1.3-1.5 bar (19- 22 psi) 19 - Coolant Control...
Page 392 Cooling system Page 7 of 20 ON: 92 - 97 C (198 - 207 F) OFF: 84 -91 (183 - 196 F) Switching temperatures: 2nd stage: ON: 99 - 105 C (210- 221 F) OFF: 91 -98 (196 - 208 F) 20 - Rubber bushing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 393 Cooling system Page 8 of 20 19-5 Cooling system components, engine side 1 - To top of radiator Page 19-2 item 4 2 - To expansion tank Page 19-5 item 17 3 - Engine Coolant Temperature (ECT) sensor - G62- With sensor G2 for...
Page 394 Cooling system Page 9 of 20 expansion tank Page 19-4 item 16 9 - To heater core 10 - To ATF cooler Vehicles with auto. trans. 11 - 10 Nm (7 ft 12 - Bracket http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 395 Cooling system Page 10 of 20 19-6 13 - From heater core 14 - From expansion tank or ATF cooler Page 19-3 item 14 15 - Coolant line 16 - Oil cooler Removing installing Page 17-3 item 12 17 - To bottom of radiator Page 19-2...
Page 396 Cooling system Page 11 of 20 Ribbed drive belt, removing installing Page 13-11 V-belt tension, adjusting: Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 48 22 - Coolant pump Disassembling assembling Page 19-7 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 397 Cooling system Page 12 of 20 19-7 Coolant pump, disassembling assembling 1 - 25 Nm (15 ft lb) 2 - Coolant pump pulley ribbed drive belt 3 - Coolant pump Make sure that shaft rotates smoothly 4 - Gasket Always replace 5 - Coolant thermostat...
Page 398 Cooling system Page 13 of 20 Opening stroke: 7 mm (0.28 in.) minimum 6 - Connector pipe http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 399 Cooling system Page 14 of 20 19-8 7 - O-ring Always replace 8 - Clip 9 - 10 Nm (7 ft 10 - Flange 11 - Coolant pump pulley For V- belt Remove install with VAG 1590 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 400 Dispose of properly. Filling Note: The cooling system of all Volkswagen vehicles is filled at the factory with a mixture of water and anti-freeze solution (G11) containing corrosion inhibitors designed for year round use. Phosphate-free antifreeze prevents...
Page 401 Cooling system Page 16 of 20 19-10 Recommended mixture ratios: Protection Anti-freeze Water percentage Vehicles with automatic transmission 3.7 liters -25 C (- liters 13 F) (3.9 qt.) (2.6 qt.) 3.1 liters -35 C (- liters 31 F) (3.3 qt.) (3.3 qt.) Vehicles with manual transmission...
Page 402 Cooling system Page 17 of 20 19-11 - Slowly fill coolant up to "MAX" mark on expansion tank. Filling time: approx. 5 minutes - Close expansion tank (install cap). - Let engine run until coolant fan comes on. - Check coolant level and top off if necessary.
Page 403 Cooling system Page 18 of 20 19-12 Radiator and coolant fan, removing and installing Special tools, testers and auxiliary items Pliers VAG 1921 for spring-type clips Removing - Drain coolant Page 19-9 - Disconnect coolant hoses from radiator. - Disconnect harness connectors from coolant fan thermal switch F18 and coolant fan.
Page 404 Cooling system Page 19 of 20 19-13 Installing Install in the reverse order of removal, noting the following: Cooling system, filling Page 19-9 Electrical connections and routing: Repair Manual, Electrical Equipment, Repair Group 97 Headlight adjustment: Repair Manual, Electrical Equipment, Repair Group 94 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 405 Cooling system Page 20 of 20 19-14 Additional information for vehicles with A/C WARNING! The A/C refrigerant is toxic. The A/C circuit must only be opened by specially trained technicians using the proper tools and equipment. CAUTION! Disconnect brackets and support points only.
Page 406 Fuel supply system Page 1 of 24 20-1 Fuel supply system General information Observe safety rules Page 20-7 Observe rules for cleanliness Page 20-9 Accelerator pedal cable Page 20-10 Note: Hose connections are secured with either screw, clamp, or spring-type hose clips. Always replace clamp-type with screw or spring-type clips.
Page 407 Fuel supply system Page 2 of 24 20-2 Fuel filter and fuel tank with attaching parts, removing and installing CAUTION! After repairs to fuel pump or fuel level sensor are complete, be sure fuel supply or return hoses do not make contact with the fuel tank (pump noises may be...
Page 408 Fuel supply system Page 3 of 24 20-3 8 - Reservoir Type shown: Wagon Basic expansion tank in Sedan 9 - Vent hose Filler vent 10 - Vent hose Fuel tank vent, for Wagon only 11 - Return hose Color: Blue From fuel rail...
Page 409 Fuel supply system Page 4 of 24 Remove install with 3217 13 - Flange Note installed position on fuel tank Page 20- Fig. 1 14 - Supply hose 15 - Sealing ring Lubricate with gasoline assemble Replace damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 410 Fuel supply system Page 5 of 24 20-4 16 - Return hose 17 - Fuel level sensor -G- 18 - Fuel Pump (FP) -G6- Removing installing Page 20-12 Checking Page 20-14 19 - Mounting strap Note different lengths 20 - Bracket mounting straps 21 - 25 Nm (18...
Page 411 Fuel supply system Page 6 of 24 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 24 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1996-1997, Repair Group 24 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 412 Fuel supply system Page 7 of 24 20-5 24 - Fuel filter Installation position: Arrow on filter points in direction of flow 25 - Retaining clip 26 - 10 Nm (7 ft 27 - Breather hose Evaporative Emissions (EVAP) canister Page 20- , item 7 28 - Gravity...
Page 413 Fuel supply system Page 8 of 24 closed http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 414 Fuel supply system Page 9 of 24 20-6 Fig. 1 Installation position fuel pump module flange Mark on flange must align with mark on fuel tank Fig. 2 Checking vent valve Lever in rest position: valve closed Lever pressed in direction of arrow: valve open http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 415 Fuel supply system Page 10 of 24 20-7 Safety precautions WARNING! When removing and installing the fuel pump or fuel level sensor from a filled or partially filled fuel tank: Fuel supply lines are under pressure! Before removing, wrap a cloth around the connection.
Page 416 Fuel supply system Page 11 of 24 Disconnect harness connectors from all fuel injectors. After the work is completed, erase Diagnostic Trouble Code (DTC) memory. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 417 Fuel supply system Page 12 of 24 20-8 CAUTION! BEFORE disconnecting the battery: Stop the engine. Be sure the ignition is switched OFF (also applies when connecting the battery). Failure to do so may damage the Engine Control Module (ECM). Be sure of the proper radio code (for vehicles equipped with coded anti-theft radio).
Page 418 Fuel supply system Page 13 of 24 20-9 Rules of cleanliness CAUTION! Whenever carrying out work on the fuel supply and fuel injection systems, carefully observe the following five rules of cleanliness. 1 - Thoroughly clean fuel system line and hose connections and the surrounding area before disconnecting.
Page 419 Fuel supply system Page 14 of 24 20-10 Accelerator pedal cable, adjusting Vehicles with manual transmission - Adjust accelerator pedal cable by moving retainer (arrow) on support bracket until throttle valve just reaches wide open throttle position when accelerator pedal is fully depressed.
Page 420 Fuel supply system Page 15 of 24 20-11 - Adjust accelerator pedal cable by moving retainer (arrow) on support bracket until throttle valve just reaches wide open throttle position when accelerator pedal is fully depressed. - Release accelerator pedal. - Connect multimeter to kickdown switch F8 using adapter cables from VW 1594 test kit.
Page 421 Fuel supply system Page 16 of 24 20-12 Fuel pump module, removing and installing Special tools, testers and auxiliary items Ring nut spanner 3217 Removing - Observe safety precautions Page 20-7 CAUTION! Determine correct radio anti-theft coding before disconnecting the battery. - With ignition switched off, disconnect battery negative cable (ground strap).
Page 422 Fuel supply system Page 17 of 24 20-13 - Loosen fuel pump module from bayonet connection by turning to the left and remove. CAUTION! If the fuel pump module is still filled with fuel, empty before replacing. Installing Install fuel pump module in reverse order of removal.
Page 423 Fuel supply system Page 18 of 24 20-14 Fuel pump, checking Special tools, testers and auxiliary items Remote control VAG 1348/3A with VAG 1348/3-2 adapter cable Voltage tester VAG 1527B Connector test kit VW 1594 Ring nut spanner 3217 Pressure tester VAG 1318 Adapter 1318/1 Adapter 1318/10 Adapter 1318/11...
Page 424 Fuel supply system Page 19 of 24 20-15 Test sequence - Switch ignition on. Fuel pump must be heard to run briefly If the fuel pump does not run: - Switch ignition off. - Remove fuel pump relay J17 from relay panel, position -12-.
Page 425 Fuel supply system Page 20 of 24 20-16 If fuel pump does not run: - Remove luggage compartment floor covering. - Disconnect harness connector from fuel tank flange. - Connect VAG 1527B voltage tester to the outer terminals of the connector using adapter cables from VW 1594 test kit.
Page 426 Fuel supply system Page 21 of 24 20-17 Fuel pump delivery rate, checking Test conditions Voltage supply OK. Remote control VAG 1348/3A connected. Test sequence - Remove fuel tank filler cap. WARNING! Fuel supply lines are under pressure! Before removing, wrap a cloth around the connection.
Page 427 Fuel supply system Page 22 of 24 20-18 - Operate VAG 1348/3A remote control and slowly close shutoff valve, until pressure gauge shows 1.2 bar (17 psi). Do not change position of shut-off valve. - Empty measuring container. - Connect multimeter to vehicle battery using adapter cables from VW 1594 test kit, then measure and record voltage.
Page 428 Fuel supply system Page 23 of 24 20-19 If the minimum delivery rate is not reached: - Check the fuel lines and hoses for possible restrictions (kinks) or blockages. - Disconnect supply hose -1- from inlet to fuel filter. - Connect VAG 1318 pressure gauge to hose with 1318/10 adapter.
Page 429 Fuel supply system Page 24 of 24 20-20 If the correct delivery rate has been reached, but you still suspect a fuel supply system malfunction (e.g. intermittent failure of fuel supply system): - Carry out a current draw test of the fuel pump as follows: - Reconnect all disconnected fuel hoses/lines.
Page 430 Evaporative Emissions (EVAP) system Page 1 of 7 20-21 Evaporative Emissions (EVAP) system Components, removing and installing 1 - Connector 2 - EVAP canister purge regulator valve -N80- Valve opens approx. 5 seconds after ignition is switched With engine warm, valve is activated Motronic...
Page 431 Evaporative Emissions (EVAP) system Page 2 of 7 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1996-1997, Repair Group 01 Engines up to 07.95 Color: blue Engines from 08.95 Color: black 3 - Bracket On air cleaner housing, lower...
Page 432 Evaporative Emissions (EVAP) system Page 3 of 7 20-22 5 - Throttle valve 6 - Breather hose From gravity valve page 20- 7 - EVAP canister Right front wheel housing Removing: press safety clasp in direction of (arrow) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 433 Evaporative Emissions (EVAP) system Page 4 of 7 20-23 Fuel tank breather, checking Special tools, testers and auxiliary items Hand vacuum pump US 8026 Test conditions Ignition switched off Test sequence - Remove air cleaner: Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection &...
Page 434 Evaporative Emissions (EVAP) system Page 5 of 7 from EVAP canister -4- and plug port on canister. - Operate hand vacuum pump US 8026 several times. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 435 Evaporative Emissions (EVAP) system Page 6 of 7 20-24 Vacuum must not build-up If vacuum builds-up: - Check breather connection -5- on EVAP canister -4- for contamination, clean if necessary. - Remove plug from EVAP canister port. - Check EVAP canister purge regulator valve N80- -6- for continuity, and replace if necessary.
Page 436 Evaporative Emissions (EVAP) system Page 7 of 7 20-25 - Operate hand vacuum pump US 8026 several times. Vacuum must not build-up Note: If the fuel level in the tank is low, hand vacuum pump may need to be operated at least 20-30 times.
Page 437 Exhaust system removal and installation Page 1 of 16 26-1 Exhaust system removal and installation Exhaust manifold, front exhaust pipe and Three Way Catalytic Converter (TWC) Page 26-2 Muffler assembly and mounts Page 26-7 Exhaust Gas Recirculation (EGR) system Page 26-10 Checking Secondary Air Injection (AIR) system Page 26-16 CAUTION!
Page 438 Exhaust system removal and installation Page 2 of 16 26-2 Exhaust manifold, front exhaust pipe and Three Way Catalytic Converter (TWC), removing and installing Vehicles up to 07.95 1 - Bracket For heat deflector 2 - 25 Nm (18 ft lb) 3 - Heat deflector 4 - 35 Nm (26...
Page 439 Exhaust system removal and installation Page 3 of 16 9 - EGR tube http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 440 Exhaust system removal and installation Page 4 of 16 26-3 10 - Heated Oxygen Sensor (HO2S) 50 Nm (37 ft lb) Lube threads with "G5": "G5" must not get into or near sensor slots Remove install with 3337 Checking Repair Manual, 2.0 Liter 4-Cyl.
Page 441 Exhaust system removal and installation Page 5 of 16 sequence Page 26-6 Fig. 1 14 - Heat shield 15 - 10 Nm (7 ft 16 - Front exhaust pipe 17 - Gasket Always replace 18 - Exhaust manifold 19 - 35 Nm (26 ft lb) Fitting Page 26-...
Page 442 Exhaust system removal and installation Page 6 of 16 26-4 Vehicles from 08.95 1 - Bracket For heat deflector 2 - 25 Nm (18 ft lb) 3 - Heat deflector 4 - Heated Oxygen Sensor (HO2S) 2 50 Nm (37 ft lb) Installation location: after three...
Page 443 Exhaust system removal and installation Page 7 of 16 Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 24 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1996-1997, Repair Group 24 5 - Three Way Catalytic Converter (TWC)
Page 444 Exhaust system removal and installation Page 8 of 16 26-5 7 - Heated Oxygen Sensor (HO2S) 1 50 Nm (37 ft lb) Installation location: before three way catalytic converter Lube threads with "G5": "G5" must not get into or near sensor slots Remove...
Page 445 Exhaust system removal and installation Page 9 of 16 Repair Group 24 8 - 40 Nm (30 ft lb) Tightening sequence Fig. 1 9 - Heat shield 10 - 10 Nm (7 ft 11 - Front exhaust pipe 12 - Gasket Always replace 13 - Exhaust...
Page 446 Exhaust system removal and installation Page 10 of 16 26-6 Fig. 1 Exhaust pipe/manifold tightening sequence http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 447 Exhaust system removal and installation Page 11 of 16 26-7 Muffler assembly and mounts Note: The exhaust system must be aligned lengthwise so that the dimensions -a-, - b- and -c- are maintained. 1 - From TWC 2 - 40 Nm (30 ft lb) 3 - Double clamp...
Page 448 Exhaust system removal and installation Page 12 of 16 marking = dimension a, - 14 - http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 449 Exhaust system removal and installation Page 13 of 16 26-8 11 - Cutting point For repair to individual exhaust components When replacing center muffler Marked by three impressions circumference of connecting pipe through connecting pipe with hack saw (e.g. VAG 1523) at right angle, at...
Page 450 Exhaust system removal and installation Page 14 of 16 circumference of connecting pipe production, center and rear muffler installed as one part. For repairs, center and rear mufflers and a connecting pipe with two clamps supplied individually. through connecting pipe with hack saw (e.g.
Page 451 Exhaust system removal and installation Page 15 of 16 26-9 13 - Dimension Approx. 10 mm (0.39 in.) 14 - Dimension Approx. 5 mm (0.20 in.) 15 - Marking Marked three times on pipe circumference 16 - Marking Marked three times on pipe circumference Manual...
Page 452 Exhaust system removal and installation Page 16 of 16 mufflers and a connecting pipe with two clamps supplied individually. 18 - Center muffler http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 453 Exhaust Gas Recirculation (EGR) system Page 1 of 7 26-10 Exhaust Gas Recirculation (EGR) system Vehicles up to 07.95 only Note: The function of the EGR system is monitored by the On Board Diagnostic system of the Motronic Engine Control Module (ECM) J220.
Page 454 Exhaust Gas Recirculation (EGR) system Page 2 of 7 26-11 9 - 30 Nm (22 ft lb) 10 - To exhaust manifold 11 - To intake manifold, upper 12 - To air cleaner housing, upper 13 - Air Cleaner (ACL) Dirty air cleaner element can...
Page 455 Exhaust Gas Recirculation (EGR) system Page 3 of 7 26-12 Exhaust Gas Recirculation (EGR) valve and EGR temperature sensor, checking Vehicles up to 07.95 only Checking activation of the EGR valve N18: Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 01 Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) with VAG...
Page 456 Exhaust Gas Recirculation (EGR) system Page 4 of 7 Measuring Value Block" function 08; Display Group 002 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 01 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 457 Exhaust Gas Recirculation (EGR) system Page 5 of 7 26-13 Test sequence VAG 1551 in "Read Measuring Value Block" function 08 Engine idling Indicated on display: (1, 2, 3 and 4 Read measuring value block 2 Display fields) 1 2 3 4 - Disconnect EGR valve vacuum hose from EGR vacuum regulator solenoid valve -1-.
Page 458 Exhaust Gas Recirculation (EGR) system Page 6 of 7 26-14 If the idle gets worse: - Read EGR temperature in display field 4. Temperature must rise steadily without interruption The value 127.4 C will be displayed if there is an interruption, or until this temperature is reached.
Page 459 Exhaust Gas Recirculation (EGR) system Page 7 of 7 26-15 - Check wiring between ECM harness connector and 2-pin connector terminal 1 for short circuit to terminal 2 and/or to ground, according to wiring diagram. Terminal 1 and test box socket 33 Specification: (no continuity) - In addition check wiring for short circuit to...
Page 460 Secondary Air Injection (AIR) system Page 1 of 24 26-16 Secondary Air Injection (AIR) system Function Vehiclesup to 07.95 The Secondary Air Injection (AIR) system directs air in behind the exhaust valve for approx. 30 seconds during a cold start (engine coolant temperature 15 to 35 C or 59 to 95 F).
Page 461 Secondary Air Injection (AIR) system Page 2 of 24 1996-1997, Repair Group 01 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 462 Secondary Air Injection (AIR) system Page 3 of 24 26-17 Secondary Air Injection (AIR) system components, removing and installing Vehicles up to 07.95 Note: The complete system is checked by the On Board Diagnostic program. Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection &...
Page 463 Secondary Air Injection (AIR) system Page 4 of 24 1 - Combi- valve Checking Page 26-23 2 - To connection on hose to vacuum brake booster 3 - Vacuum hose 4 - Harness connector 2-pin http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 464 Secondary Air Injection (AIR) system Page 5 of 24 26-18 5 - Secondary Injection (AIR) solenoid valve - N112-** Checking Page 26-29 6 - T- connector 7 - Vacuum hose 8 - Check valve 9 - Pressure hose Connection should be tight and free of leaks...
Page 465 Secondary Air Injection (AIR) system Page 6 of 24 line 15 - To fitting exhaust manifold Page 26-3 item 19 16 - 10 Nm (7 ft http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 466 Secondary Air Injection (AIR) system Page 7 of 24 26-19 17 - Bracket combi- valve 18 - 25 Nm (18 ft lb) 19 - 10 Nm (7 ft 20 - Pressure hose Connection should be tight and free of leaks 21 - Bracket secondary injection...
Page 467 Secondary Air Injection (AIR) system Page 8 of 24 V101-** Checking Page 26-24 27 - To Air Cleaner (ACL) 28 - Intake air hose secondary injection pump motor - 26 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 468 Secondary Air Injection (AIR) system Page 9 of 24 26-20 Vehicles from 08.95 Note: The complete system is checked by the On Board Diagnostic program. Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 01 Repair Manual, 2.0 Liter 4-Cyl.
Page 469 Secondary Air Injection (AIR) system Page 10 of 24 2-pin 5 - Secondary Injection (AIR) solenoid valve - N112- Checking Page 26-23 6 - Pressure hose Connection should be tight and free of leaks http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 470 Secondary Air Injection (AIR) system Page 11 of 24 26-21 7 - Bracket secondary injection pump motor - 12 8 - 10 Nm (7 ft 9 - Bracket For A/C hose 10 - 10 Nm (7 ft 11 - 25 Nm (18 ft lb) 12 - Secondary Injection...
Page 471 Secondary Air Injection (AIR) system Page 12 of 24 15 - To fitting exhaust manifold Page 26-5 item 14 16 - 30 Nm (22 ft lb) 17 - Air injection line 18 - 10 Nm (7 ft http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 472 Secondary Air Injection (AIR) system Page 13 of 24 26-22 19 - 10 Nm (7 ft 20 - Bracket combi- valve 21 - 25 Nm (18 ft lb) 22 - Gasket Always replace 23 - Union http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 473 Secondary Air Injection (AIR) system Page 14 of 24 26-23 Combi-valve and check valve, checking Special tools, testers and auxiliary items US 8026 hand vacuum pump Test sequence - Disconnect vacuum hose -1- from secondary air injection solenoid valve -2-. - Connect US 8026 hand vacuum pump to vacuum hose -1-.
Page 474 Secondary Air Injection (AIR) system Page 15 of 24 26-24 Secondary Air Injection (AIR) pump motor, checking Special tools, testers and auxiliary items VAG 1598/18 test box VW 1594 connector test kit VAG 1527B voltage tester Test conditions Fuse -3- on secondary air injection pump relay J299 -4- OK Test sequence Vehicles up to 07.95...
Page 475 Secondary Air Injection (AIR) system Page 16 of 24 26-25 Vehicles up to 07.95 - Switch ignition off. - Connect VAG 1598/18 test box to ECM wiring harness. - Disconnect pressure hose from check valve -1-. - Switch ignition on. - Connect test box sockets 1 and 50 using adapter cables from VW 1594 connector test kit.
Page 476 Secondary Air Injection (AIR) system Page 17 of 24 26-26 If the motor does not run: - Disconnect 2-pin connector from secondary air injection pump motor V101. - Connect VAG 1527B voltage tester to 2-pin connector using adapter cables from VAG 1594 test kit.
Page 477 Secondary Air Injection (AIR) system Page 18 of 24 26-27 Vehicles from 08.95 - Switch ignition off. - Connect VAG 1598/18 test box to ECM wiring harness. - Disconnect pressure hose from combi-valve -1-. - Switch ignition on. - Bridge test box sockets 1 and 06 using adapter cables from VW 1594 connector test kit.
Page 478 Secondary Air Injection (AIR) system Page 19 of 24 26-28 LED must light up If YES (voltage supply OK): - Replace secondary air injection pump motor. If LED does NOT light up: - Check wiring between test box socket 49 and secondary air injection pump relay using wiring diagram.
Page 479 Secondary Air Injection (AIR) system Page 20 of 24 1996-1997, Repair Group 01 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 480 Secondary Air Injection (AIR) system Page 21 of 24 26-29 Secondary Air Injection (AIR) solenoid valve, checking Vehicles up to 07.95 Special tools, testers and auxiliary items VW 1594 connector test kit VAG 1527 voltage tester Test conditions Engine oil temperature 15-35 C (59-95 F) Secondary air injection pump motor Test sequence...
Page 481 Secondary Air Injection (AIR) system Page 22 of 24 26-30 - Connect VAG 1527B voltage tester to 2-pin connector using adapter cables from VW 1594 connector test kit. - Start engine and run at idle. LED must light-up If YES (voltage supply OK): - Replace secondary air injection solenoid valve If LED does not light up: - Reconnect 2-pin connector.
Page 482 Secondary Air Injection (AIR) system Page 23 of 24 26-31 Vehicles from 08.95 Special tools, testers and auxiliary items VW 1594 connector test kit VAG 1527 voltage tester US 8026 Hand vacuum pump Test conditions Vacuum hoses OK Test sequence - Disconnect vacuum hose to secondary air injection solenoid valve at vacuum line to brake servo, item - 2 -...
Page 483 Secondary Air Injection (AIR) system Page 24 of 24 26-32 Vacuum must build up (valve closed) If vacuum builds up: - Disconnect 2-pin connector from solenoid valve. - Connect VAG 1527B voltage tester to 2-pin harness connector using adapter cables from VW 1594 connector test kit.
Page 486 2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AAA 00 - General, Technical data Technical data Engine number Engine data 10 - Engine - Assembly Engine, removing and installing Vehicles with A/C Vehicles with manual transmission Vehicles with automatic transmission All vehicles: Installation notes Tightening torques...
Page 487 Valve train, servicing Valve seats, reworking Camshafts, removing and installing Hydraulic lifters, checking Valve guides, checking Valve guides, replacing Valve stem seals, replacing 17 - Engine - Lubrication Lubrication system, component removal and installation Oil filter housing, disassembling and assembling Oil pump, disassembling and assembling Oil pressure and oil pressure switch, checking 19 - Engine - Cooling system...
Page 488 Exhaust gas recirculation system Exhaust Gas Recirculation (EGR) valve, checking Secondary Air Injection system, function Secondary Air Injection system components, removing and installing Combi-valve, checking Secondary Air Injection pump motor, checking Secondary Air Injection solenoid valve, checking Combi-valve and Secondary Air Injection pump motor, removing and installing...
Page 489 Technical data Page 1 of 3 00-1 Technical data Engine number The engine number ("Code letters" and "Serial number") can be found on the vibration damper end of the cylinder block. There is also a sticker on the cylinder head cover that shows the "Engine code"...
Page 490 Technical data Page 2 of 3 00-2 Engine data Engine code Manufactured 10.93 Arrangement of cylinders Cylinder angle Displacement ltrs. Output kW at rpm 128/5800 Torque Nm at rpm 235/4200 (240/4200) Bore diameters mm 81 Stroke 90.3 Compression ratio 10.0 : 1 VR = V-arrangement in compact in-line design Note: The design of this engine management system, with selective knock control, permits the full use of high octane fuel.
Page 491 Technical data Page 3 of 3 00-3 Engine code minimum 95 unleaded Injection system Motronic Ignition system Motronic Firing order 1-5-3-6-2-4 Knock control On Board Diagnostic Oxygen sensor control Three-way Catalyst http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 492 Engine, removing and installing Page 1 of 16 10-1 Engine, removing and installing Removing: - Remove the engine in a forward direction (together with the transmission) - Switch off the ignition and disconnect the battery ground wire. Note: First obtain the radio anti-theft code from the customer before disconnecting the battery.
Page 493 Engine, removing and installing Page 2 of 16 10-2 - Disconnect accelerator cable at throttle valve housing and support bracket (do not remove locating clip at support bracket). - Loosen power steering reservoir hose clamp. - Unbolt power steering hydraulic line retainers from engine mount and transmission.
Page 494 Engine, removing and installing Page 3 of 16 10-3 Note: For protection against fuel spray cover connections with a cloth. - Separate 4-pin connector to Oxygen sensor and 2-pin connector to knock sensor 1 on rear right assembly mounting. - Unbolt drive shafts and tie up. - Remove balance weight and front exhaust pipe from exhaust manifold, Page 26-2...
Page 495 Engine, removing and installing Page 4 of 16 10-4 Vehicles with A/C - Additional information and removal instructions Page 10-16 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 496 Engine, removing and installing Page 5 of 16 10-5 Vehicles with manual transmission Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 Remove hydraulic clutch slave cylinder Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 34; Remove transmission operating cables with support bracket from transmission - Attach lifting tackle 2024 A as follows and lift engine and trans assembly...
Page 497 Engine, removing and installing Page 6 of 16 10-6 Vehicles with automatic transmission Repair Manual, Automatic Transmission, Repair Group 37; Remove selector lever cable from transmission - Attach lifting tackle 2024A with extension 2024 All as follows and lift power train slightly using workshop crane: Vibration damper end: 1st hole in extension at position 1...
Page 498 Engine, removing and installing Page 7 of 16 10-7 All vehicles: - Release transmission from left-rear assembly mounting and engine from right-rear assembly mounting. - Release engine at front assembly mounting. - Disconnect engine carrier on one side pry the spacer bracket out of the rubber mountings.
Page 499 Engine, removing and installing Page 8 of 16 10-8 Installation notes Installation is the reverse of the removal sequence. Note the following points during installation: Vehicles with manual transmission - Check clutch release bearing for wear, replace if necessary. - Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100.
Page 500 Engine, removing and installing Page 9 of 16 10-9 Vehicles with manual transmission Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30; Install hydraulic clutch slave cylinder Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 34; Install selector cables with support bracket on transmission, adjust if necessary Vehicles with automatic transmission Repair Manual, Automatic Transmission,...
Page 501 Engine, removing and installing Page 10 of 16 10-10 Repair Manual, Body Exterior, Interior, Repair Group 50; Install lock carrier with attachments Repair Manual, Electrical Equipment, Repair Group 97; Electrical connections and routing Repair Manual, 2.8 Liter VR6 2V Fuel Injection &...
Page 502 Engine, removing and installing Page 11 of 16 10-11 Tightening torques Component Tightening torque Engine to transmission 60 Nm (44 ft lb) 80 Nm (59 ft lb) Drive shafts to flanged shafts 45 Nm (33 ft lb) Front exhaust pipe to exhaust manifold 40 Nm (30 ft lb) Front exhaust pipe to three-way catalyst...
Page 503 Engine, removing and installing Page 12 of 16 10-12 Engine/transmission mounts Tightening torques(with threads lubricated) Front engine transmission mounts A = 60 Nm (44 ft lb) B = 60 Nm (44 ft lb) C = 55 Nm (41 ft lb) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 504 Engine, removing and installing Page 13 of 16 10-13 Right rear engine/transmission mount A = 60 Nm (44 ft lb) B = 60 Nm (44 ft lb) C = 25 Nm (18 ft lb) Left rear engine/transmission mount A = 60 Nm (44 ft lb) B = 25 Nm (44 ft lb) C = 25 Nm (18 ft lb) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 505 Engine, removing and installing Page 14 of 16 10-14 Engine and transmission, aligning Aligning is only necessary when the engine and transmission have been removed and if the rubber mounts have been loosened at the engine and trans mount and engine mount. - Loosen right-rear engine and trans mount -A- at engine and sub-frame.
Page 506 Engine, removing and installing Page 15 of 16 10-15 Rubber engine mount, replacing - Disconnect high tension wires from ignition coil and unclip wire from wire guide -2-. - Remove high tension wire guide -2-. - Pull off vacuum hose between intake manifold upper section and fuel pressure regulator.
Page 507 Engine, removing and installing Page 16 of 16 10-16 A/C components, removing CAUTION! The A/C refrigerant circuit must not be opened. Note: Only open up the A/C refrigerant circuit in workshops, having trained personnel and the necessary range of tools and equipment to complete the work.
Page 508 Engine, disassembly and assembly Page 1 of 71 13-1 Engine, disassembly assembly Note: When repairing an engine, metal shavings or large quantities of small metal particles are found in engine oil; (for example, caused by partial seizure of crankshaft and connecting rod bearings) to prevent damage it is...
Page 509 Engine, disassembly and assembly Page 2 of 71 13-2 Part I 1 - Camshaft sprocket double chain (item 18 ) Removing installing Page 15-23 removing installing camshafts 2 - Wheel sensor Camshaft Position sensor - G40- Contact surface of timing chain wheel sensor...
Page 510 Engine, disassembly and assembly Page 3 of 71 camshafts 3 - 100 Nm (74 ft lb) remove and install counter- hold with 24 mm open end wrench camshaft Page 15-23 removing installing camshafts Oil the bolt head contact surface when installing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 511 Engine, disassembly and assembly Page 4 of 71 13-3 4 - Pivot pin, 25 Nm (18 ft lb) tensioner plate, item 16 5 - Seal Always replace 6 - Chain tensioner 30 Nm (22 ft lb) double chain (item 18 ) Bleed before installing...
Page 512 Engine, disassembly and assembly Page 5 of 71 chain, (item 24 ) Installing Page 13-24 adjusting valve timing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 513 Engine, disassembly and assembly Page 6 of 71 13-4 9 - Double chain Mark direction rotation before removing (installed position) Fig. 1 Installing Page 13-24 adjusting valve timing 10 - 100 Nm (74 ft lb) 11 - Sprocket double chain (item 18 ) Installing Page...
Page 514 Engine, disassembly and assembly Page 7 of 71 Before installing, release locking spline in chain tensioner with a small screwdriver and press tensioning plate against chain tensioner Only rotate engine with chain tensioner installed http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 515 Engine, disassembly and assembly Page 8 of 71 13-5 14 - Crankshaft sprocket Integral part of crankshaft Machine down tooth aligned with main bearing joint = TDC for No. 1 Cyl. Page 13- adjusting valve timing 15 - Single chain Mark direction of rotation...
Page 516 Engine, disassembly and assembly Page 9 of 71 Remove together with single chain Page 13- adjusting valve timing 17 - Locating without collar 25 Nm (18 ft lb) For guide rail (item 25 ) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 517 Engine, disassembly and assembly Page 10 of 71 13-6 18 - Locating pin with collar 25 Nm (18 ft lb) For guide rail (item 30 ) 19 - 20 Nm (15 ft lb) Insert with locking fluid "D6" 20 - 20 Nm (15 ft lb) 21 - Guide rail double...
Page 518 Engine, disassembly and assembly Page 11 of 71 13-7 Fig. 1 Marking single and double chains - Mark single and double chains before removing them (paint or mark an arrow pointing in direction of normal engine rotation). Note: Do not mark the chain using a center punch or with any method that scratches or deforms the metal surfaces.
Page 519 Engine, disassembly and assembly Page 12 of 71 13-8 Part II 1 - 5 Nm (44 in. Ib) 2 - Cover Over upper section of intake manifold 3 - Ignition wire guide 4 - Rear left support Between upper section of intake manifold cylinder...
Page 520 Engine, disassembly and assembly Page 13 of 71 for fuel lines 7 - Cap 8 - Seal Replace damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 521 Engine, disassembly and assembly Page 14 of 71 13-9 9 - Hose crankcase breather crankcase breather valve 10 - Cylinder head cover Removing installing Page 15-9 11 - O-Ring Always replace Coat with oil before assembling and insert camshaft sprocket cover (item 12 ) 12 - Camshaft...
Page 522 Engine, disassembly and assembly Page 15 of 71 sprocket cover has been removed, prepare cylinder head gasket assembly Page 15-8 Fig. 2 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 523 Engine, disassembly and assembly Page 16 of 71 13-10 13 - Chain tensioner 30 Nm (22 ft lb) double chain Bleed before installing Page 13-7 Fig. 2 Only turn engine with chain tensioner install 14 - Seal Always replace 15 - Bracket For 42- connector and pump...
Page 524 Engine, disassembly and assembly Page 17 of 71 electric wires http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 525 Engine, disassembly and assembly Page 18 of 71 13-11 20Thermostat housing Disassembling assembling % Page 19-10 21 - O-Ring Always replace 22 - Cylinder head gasket Always replace replaced; also replace complete engine coolant 23 - Cylinder head Removing installing Page 15- replaced;...
Page 526 Engine, disassembly and assembly Page 19 of 71 Always replace Note sequence when loosening tightening Page 15-11 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 527 Engine, disassembly and assembly Page 20 of 71 13-12 25 - Lifting eye 26 - Intake manifold - lower section 27 - Gasket for intake manifold lower section Always replace 28 - Ribbed belt tensioner Removing installing ribbed belts Page 13- 29 - Cylinder head cover...
Page 528 Engine, disassembly and assembly Page 21 of 71 Always replace http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 529 Engine, disassembly and assembly Page 22 of 71 13-13 32 - Intake manifold upper section First tighten intake manifold lower section, then the two rear supports, (items 4 and 6 ) 33 - Vacuum hose To brake servo http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 530 Engine, disassembly and assembly Page 23 of 71 13-14 Part III 1 - 10 Nm (7 ft 2 - Oil pump drive cover 3 - O-Ring Always replace Lubricate with oil before assembling 4 - Oil pump drive 5 - Cylinder block Removing and installing...
Page 531 Engine, disassembly and assembly Page 24 of 71 7 - Thrust washer http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 532 Engine, disassembly and assembly Page 25 of 71 13-15 8 - 10 Nm (7 ft Insert using locking "D6" fluid 9 - Knock sensor 2 - G66- Checking, Repair Group 01 10 - 20 Nm (15 ft lb) Tightening torque influences function of the knock...
Page 533 Engine, disassembly and assembly Page 26 of 71 surface of sensor with AMV 74 004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 534: Cooling System
Engine, disassembly and assembly Page 27 of 71 13-16 14 - Gasket Replace damaged Before installing gasket, coat sump flange/cylinder block flange with "D2" 15 - Coolant line thermostat housing Page 13- (item 19 ) Removing installing Page 19-5 parts of cooling system - engine...
Page 535 Engine, disassembly and assembly Page 28 of 71 cylinder block and oil pump housing with AMV 188 001 18 - 25 Nm (18 ft lb) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 536: Oil Cooler
Engine, disassembly and assembly Page 29 of 71 13-17 19 - 10 Nm (7 ft Insert with locking "D6" fluid 20 - Seal Always replace 21 - Oil drain plug 30 Nm (22 ft lb) Replace if leaking. See Parts Catalog for correct application.
Page 537 Engine, disassembly and assembly Page 30 of 71 25 Nm (18 ft lb) 25 - Oil cooler Coat contact area outside the seal with AMV 188 100 Make sure clearance with adjacent components See note Page 13-1 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 538: Removing And
Engine, disassembly and assembly Page 31 of 71 13-18 26 - Oil filter housing Disassembling assembling Page 17-8 27 - Gasket Always replace Note installation position Lubricate with oil before installing 28 - Vibration damper Removing installing ribbed belt Page 13- 29 - 120 Nm (88 ft lb) + turn (90 )
Page 539 Engine, disassembly and assembly Page 32 of 71 Check shaft for ease of movement Removing installing Page 19-17 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 540 Engine, disassembly and assembly Page 33 of 71 13-19 31 - 20 Nm (15 ft lb) 32 - Pulley coolant pump 33 - 25 Nm (18 ft lb) V.A.G 1590 to loosen tighten Modify water pump wrench 1590 Page 19- Fig.
Page 541 Engine, disassembly and assembly Page 34 of 71 See note Page 13-1 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 542 Engine, disassembly and assembly Page 35 of 71 13-20 Ribbed belt, removing and installing Note: When installing the ribbed belt, make sure that it is correctly seated in the pulley. Removing - Disconnect EVAP canister purge regulator valve 1 -N80- with retaining ring from air cleaner lower section Page 20-21 - Remove air cleaner housing complete with Mass...
Page 543 Engine, disassembly and assembly Page 36 of 71 13-21 Installing Note: Before installing the ribbed belt make sure that all sub-assemblies (generator, A/C compressor and power steering pump) are tight. - Install ribbed belt. - Remove M8 bolt from the tensioner! - Install air cleaner housing complete with Mass Air Flow sensor -G70-.
Page 544 Engine, disassembly and assembly Page 37 of 71 13-22 Valve timing, checking - Set crankshaft to TDC No. 1 Cyl. marks by turning crankshaft on the vibration damper securing bolt in engine D.O.R.: Vehicles with manual transmission and engine installed Mark on the pressure plate (triangular tooth) must align with the reference point cast in clutch housing...
Page 545 Engine, disassembly and assembly Page 38 of 71 13-23 Vehicles with automatic transmission and engine installed Note: The torque converter has 3 TDC No. 1 cylinder marks -arrow-, as the hole pattern for securing the torque converter allows it to be installed in three different positions.
Page 546 Engine, disassembly and assembly Page 39 of 71 13-24 - The camshaft jig 3268 must index in both shaft grooves. Note: This condition is only possible every 2nd TDC position. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 547 Engine, disassembly and assembly Page 40 of 71 13-25 Valve timing, adjusting (with timing chains removed) Engine removed Install single chain and chain tensioner with tensioning plate: - Set and check position of crankshaft to intermediate shaft. Machine tooth on crankshaft sprocket -B- must align with the main bearing joint (TDC No.
Page 548 Engine, disassembly and assembly Page 41 of 71 13-26 - Install guide rail -2- with single chain -1- and both sprockets -3- and -4- (note direction of rotation of single chain Page 13-7 Fig. 1 The marking on single chain sprocket 4 must align with the notch -C- or -D- on the thrust washer.
Page 549 Engine, disassembly and assembly Page 42 of 71 13-27 All vehicles - Tighten intermediate shaft sprockets 3 and 4 ( Page 13-24 , illustration V13-1052) to 100 Nm (74 ft lb). - Remove flywheel and drive plate and check position of crankshaft to intermediate shaft. Install double chain and chain tensioner with tensioning plate: - Locate camshafts with camshaft jig 3268.
Page 550 Engine, disassembly and assembly Page 43 of 71 13-28 - Place guide rail on locating pin. Insert short securing bolt with locking fluid "D6" and tighten both bolts to 20 Nm (15 ft lb). - Place double chain on intermediate shaft. (Note direction of rotation of double chain Page 13- Fig.
Page 551 Engine, disassembly and assembly Page 44 of 71 13-29 Note: Only counter-hold with 24 mm open end wrench on the camshaft -arrow-. The camshaft jig must not be installed when tightening and loosening the sprockets. - Coat sealing surface of sealing flange with AMV 188 001 02 and install.
Page 552 Engine, disassembly and assembly Page 45 of 71 13-30 Notes: If the chain tensioner has been pulled apart, bleed chain tensioner before installing Page 13-7 Fig. 2 Only turn engine with chain tensioner installed! Otherwise single or double chain will jump! - Turn crankshaft two full turns in direction of engine running and check valve timing Page...
Page 553: Prepare Cylinder Head Gasket For Assembly
Engine, disassembly and assembly Page 46 of 71 13-31 - Prepare cylinder head gasket for assembly Page 15-8 Fig. 2 - Install cylinder head Page 15-11 - Place guide rail on locating pin. Insert short securing bolt with locking fluid "D6" and tighten bolts to 20 Nm (15 ft lb).
Page 554: Oil O-Ring ( Page 13-9 , Item 11 )
Engine, disassembly and assembly Page 47 of 71 13-32 Note: Only counter-hold with 24 mm open end wrench on the camshaft -arrow-. The camshaft jig must not be installed when tightening and loosening the sprockets. - Coat sealing surface of sealing flange with AMV 188 001 02.
Page 555 Engine, disassembly and assembly Page 48 of 71 13-33 Flywheel sealing flange and drive plate, removing and installing Note: The sealing flange (item 7 ) can be removed and installed with the cylinder head installed. Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30;For...
Page 556 Engine, disassembly and assembly Page 49 of 71 13-34 4 - Oil seal Replacing Page 13-36 5 - Sealing flange Coat sealing surfaces with AMV 188 001 6 - Cylinder block Removing installing crankshaft Page 13-40 Disassembling assembling pistons and connecting rods Page...
Page 557 Engine, disassembly and assembly Page 50 of 71 13-35 8 - Oil seal Remove with 2086 Lightly oil sealing Install over sleeve 2003/2A Pull in onto stop with 2003/3 Flywheel/drive plate remove install counter- hold with VW 558 Removing installing drive plate Page 13-...
Page 558 Engine, disassembly and assembly Page 51 of 71 coolant hose http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 559 Engine, disassembly and assembly Page 52 of 71 13-36 Crankshaft oil seal - vibration damper end, replacing Removing - Remove ribbed belt Page 13-20 - Remove vibration damper. Lock vibration damper using tool 3273. - Unscrew inner part of oil seal extractor 3203 three turns (approx.
Page 560 Engine, disassembly and assembly Page 53 of 71 13-37 - Press in oil seal up to stop with press sleeve from 3266. To do this use an old vibration damper securing bolt. - Install vibration damper and lock using counter-hold tool 3273. - Tighten new securing bolt to 100 Nm (74 ft lb) and then turn turn (90 )
Page 561 Engine, disassembly and assembly Page 54 of 71 13-38 Drive plate, removing and installing Loosening and tightening - Secure counter-hold tool VW 558 to the drive plate with a hex bolt M8x45. Place two M10 hex nuts between counter-hold tool and drive plate. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 562 Engine, disassembly and assembly Page 55 of 71 13-39 Installing - Install drive plate to crankshaft. - Insert at least 3 old securing bolts and tighten to 30 Nm (22 ft lb). - Using a straight edge and depth gauge, check dimension -a- through the three holes for securing the torque converter and calculate the average.
Page 563 Engine, disassembly and assembly Page 56 of 71 13-40 Crankshaft, removing and installing 1 - Bearing Bearing cap 1: Vibration damper Bearing cap 5 with recesses for thrust washers Bearing shell retaining lugs cylinder block/bearing cap must be on the same side 2 - 30 Nm (22 ft lb) +...
Page 564 Engine, disassembly and assembly Page 57 of 71 without groove cylinder block with oil groove Do not interchange used bearing shells (mark) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 565 Engine, disassembly and assembly Page 58 of 71 13-41 4 - Thrust washer bearing cap 5 Note orientation 5 - Crankshaft Axial clearance new: 0.07...0.23 mm Wear limit: 0.30 Check radial clearance with Plastigage New: 0.02...0.06 Wear limit: 0.10 mm Do not rotate the crankshaft...
Page 566 Engine, disassembly and assembly Page 59 of 71 53.958 ... 53.978 mm rework is permitted 6 - Trigger wheel Engine Speed sensor - G28- Always replace 7 - 10 Nm (7 ft Ib) + turn 90 further Always replace http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 567: Oil Spray Jet
Engine, disassembly and assembly Page 60 of 71 13-42 8 - Thrust washer cylinder block, bearing 5 Note fixing arrangement 9 - Oil spray crankshaft bearings 2...7 piston cooling Opening pressure: 2.0 bar Removing installing Page 17-7 Fig. 1 See note Page 13-1 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 568 Engine, disassembly and assembly Page 61 of 71 13-43 Pistons and connecting rods, disassembling assembling 1 - Piston ring Offset gaps by Remove install with piston ring pliers "TOP" faces toward piston crown Checking ring gap Fig. 1 Checking ring to groove clearance Fig.
Page 569 Engine, disassembly and assembly Page 62 of 71 cylinder number High point of piston crown faces to center of engine block Install with piston installing tool 3278 Fig. 5 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 570 Engine, disassembly and assembly Page 63 of 71 13-44 3 - Connecting Only replace as a set Mark cylinder number - Installation position: Marks -A- must be above one another 4 - Conrod bearing Note installation position 5 - 30 Nm (22 ft lb) + turn 90 further...
Page 571 Engine, disassembly and assembly Page 64 of 71 further http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 572 Engine, disassembly and assembly Page 65 of 71 13-45 6 - Bearing shell Note installation position Do not interchange used bearing shells The lugs on the bearing shells must fit tightly in recesses Axial clearance New: 0.05...0.31 Wear limit: 0.40 mm Check radial clearance...
Page 573 Engine, disassembly and assembly Page 66 of 71 checking radial clearance 7 - Cylinder block Checking cylinder bores Fig. 4 Piston and cylinder dimensions Page 13-50 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 574 Engine, disassembly and assembly Page 67 of 71 13-46 8 - Piston pin If difficult remove, heat piston to 60 C Remove install with VW 222A 9 - Circlip http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 575 Engine, disassembly and assembly Page 68 of 71 13-47 Fig. 1 Checking piston ring gap - Push ring squarely from above down to approx. 15 mm from bottom end of cylinder. To do this use a piston without rings. Piston ring Wear limit Compression...
Page 576 Engine, disassembly and assembly Page 69 of 71 13-48 Fig. 3 Checking piston Measure pistons approx. 6 mm from the lower edge of skirt, at 90 to the piston pin axis Deviation from nominal dimension max. 0.04 mm Fig. 4 Checking cylinder bores Measure bores at 3 locations in both directions -A- across the engine and...
Page 577 Engine, disassembly and assembly Page 70 of 71 13-49 Fig. 5 Installing pistons with piston installion tool 3278 Note: If a new tool is used to install the pistons, first pass a piston with oiled piston rings two times through the tool and then remove the metal shavings.
Page 578 Engine, disassembly and assembly Page 71 of 71 13-50 Piston and cylinder dimensions Honing Piston- Cylinder dimension diameter bore- diameter Basic dimen. 80.985 81.01 1st oversize 81.485 81.51 2nd oversize 81.985 82.01 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 579 Cylinder head, removing and installing Page 1 of 16 15-1 Cylinder head, removing installing Checking compression Page 15-12 Note: When installing an exchange cylinder head with camshaft installed, oil the contact surfaces between the hydraulic lifter and cam after installation. The plastic protectors installed to...
Page 580 Cylinder head, removing and installing Page 2 of 16 1 - 5 Nm (44 in. Ib) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 581 Cylinder head, removing and installing Page 3 of 16 15-2 2 - Ignition wire guide 3 - 25 Nm (18 ft lb) 4 - Right rear support Between intake manifold upper section cylinder head With bracket for fuel lines 5 - Bracket For fuel lines 6 - Flame trap...
Page 582 Cylinder head, removing and installing Page 4 of 16 15-3 11 - 12Cylinder head cover Removing installing Page 15-9 13 - Cylinder head cover gasket Always replace Note installed position 14 - O-Ring Always replace Lubricate before installing insert in camshaft sprocket cover...
Page 583 Cylinder head, removing and installing Page 5 of 16 Position sensor - G40- Checking http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 584 Cylinder head, removing and installing Page 6 of 16 15-4 18 - Bracket For 42- connector and pump auxiliary coolant circulation 19 - Ignition coil -N152- Checking 20 - Chain tensioner 30 Nm (22 ft lb) double chain Bleed before installing Page 13-7...
Page 585 Cylinder head, removing and installing Page 7 of 16 surfaces with AMV 188 001 If the camshaft sprocket cover has been removed, prepare cylinder head gasket assembly Fig. 2 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 586 Cylinder head, removing and installing Page 8 of 16 15-5 23 - Cylinder head gasket Always replace replaced, replace complete coolant 24 - Cylinder head Check distortion Fig. 1 Installing Page 15-11 replaced, the entire engine coolant must be replaced with new coolant.
Page 587 Cylinder head, removing and installing Page 9 of 16 26 - lntake manifold lower section gasket Always replace 27 - Lifting eye http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 588 Cylinder head, removing and installing Page 10 of 16 15-6 28 - Intake manifold - lower section 29 - Ribbed belt tensioner Removing installing ribbed belt Page 13- 30 - Intake manifold upper section gasket Always replace 31 - Intake manifold upper section...
Page 589 Cylinder head, removing and installing Page 11 of 16 10 Nm (7 ft lb) Checking http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 590 Cylinder head, removing and installing Page 12 of 16 15-7 33 - Left rear support Between intake manifold upper section cylinder head With engine ground connection 34 - Cover Above intake manifold upper section http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 591 Cylinder head, removing and installing Page 13 of 16 15-8 Fig. 1 Checking cylinder head for distortion Max. permissible distortion: 0.1 mm Fig. 2 Preparing cylinder head gasket for assembly - Remove old sealant from 3 mm holes in the cylinder head gasket-arrows-. - Fill 3 mm holes in the cylinder head gasket with sealant AMV 188 001 02 Note:...
Page 592 Cylinder head, removing and installing Page 14 of 16 15-9 Cylinder head cover, removing and installing Removing Repair Manual, 2.8 Liter VR6 2V Fuel Injection & Ignition, Repair Group 28; Remove spark plug connectors along with ignition wires - Remove ignition wire guides -1- and - - Remove cover above intake manifold upper section -3-.
Page 593 Cylinder head, removing and installing Page 15 of 16 15-10 - Remove vacuum hose off fuel pressure regulator. - Remove vacuum hose off brake servo. - Unclip fuel lines from cylinder head cover. - Detach dipstick guide tube on intake manifold lower section.
Page 594 Cylinder head, removing and installing Page 16 of 16 15-11 Cylinder head, installing No. 1 Cyl. piston at TDC Page 13-21 - Locate camshafts using camshaft jig 3268. - Install cylinder head gasket. Observe position of locating dowels in cylinder block (hole 12 and 20, illustration V15-0817).
Page 595 Compression testing Page 1 of 1 15-12 Compression testing Engine oil temperature 30 C (86 F) minimum. - Disconnect 5 pin harness connector from ignition coil -N152-. - Fully open throttle body. - Check compression using compression tester V.A.G 1381 / V.A.G 1763. Note: See operating instructions for using the compression tester that are supplied by the tool...
Page 596 Valve train, servicing Page 1 of 22 15-13 Valve train, servicing Note: Cylinder heads which have cracks between the valve seats or between valve seat inserts, and the spark plug thread can be used without reducing service life, provided the cracks do not exceed a maximum of 0.5...
Page 597 Valve train, servicing Page 2 of 22 15-14 3 - Camshafts Checking axial clearance Fig. 1 Removing installing Page 15-23 Checking radial clearance with Plastigage Wear limit: 0.1 mm Run-out: max. 0.01 mm 4 - Camshaft sprocket Removing installing Page 15-23 5 - Trigger wheel...
Page 598 Valve train, servicing Page 3 of 22 chain trigger wheel must be Removing installing Page 15-23 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 599 Valve train, servicing Page 4 of 22 15-15 6 - 7100 Nm (74 ft lb) remove install counter- hold with 24 mm open end wrench camshaft Page 15-23 When installing bulkhead contact surface 8 - Cylinder head deck height Minimum height: a = 139.5 9 - Cylinder...
Page 600 Valve train, servicing Page 5 of 22 only lapping is permitted Valve dimensions Fig. 3 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 601 Valve train, servicing Page 6 of 22 15-16 11 - Valve guide Checking Page 15-29 Replacing Page 15-29 Service version with collar 12 - Valve stem seal Replacing Page 15-30 13 - 12-Valve springs Removing installing: With cylinder head removed: use 2037 With cylinder...
Page 602 Valve train, servicing Page 7 of 22 15-17 16 - Hydraulic lifter Do not interchange With hydraulic valve clearance compensation Checking Page 15-26 Store with contacting surface downward Before installing check camshaft axial clearance Fig. 1 contact surface http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 603 Valve train, servicing Page 8 of 22 15-18 Fig. 1 Camshafts axial clearance, checking Wear limit: max. 0.15 mm Check with hydraulic lifters removed and with first and last bearing caps installed for the appropriate camshaft. Fig. 2 Installed position of camshaft bearing caps The bearing cap identification must be readable from the exhaust side of the...
Page 604 Valve train, servicing Page 9 of 22 15-19 Fig. 3 Valve dimensions Note: Valves must not be reworked. Only lapping is permitted. Dimension Inlet Exhaust valve valve diameter a 39.0 34.20 diameter b 6.97 6.95 105.95 106.95 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 605 Valve train, servicing Page 10 of 22 15-20 Valve seats, reworking Note: When repairing engines with leaking valves, it is not sufficient to rework or replace valve seats and valves. It is also necessary to check the valve guides for wear. This is particularly pertinent on high mileage engines.
Page 606 Valve train, servicing Page 11 of 22 15-21 Maximum reworking dimension, calculating - Insert valve and press firmly against seat. Note: If the valve is to be replaced as part of a repair, use a new valve for the calculation. - Measure distance -a- between end of valve stem and upper edge of cylinder head.
Page 607 Valve train, servicing Page 12 of 22 15-22 Reworking inlet valve seat a = diameter 38.3 mm b = Max. permissible reworking dimension c = 1.4... to...2.0 mm If necessary rework valve seat insert with 75 correction cutter Z = Cylinder head lower edge = 45 valve seat angle = 30 upper correction angle = 75 lower correction angle...
Page 608 Valve train, servicing Page 13 of 22 15-23 Camshafts, removing and installing Removing - Set engine to TDC for Cyl 1. marks by turning in engine running direction on the vibration damper securing bolt Page 13-21 - Remove cylinder head cover Page 15-9 Repair Manual, 2.8 Liter VR6 2V Fuel Injection &...
Page 609 Valve train, servicing Page 14 of 22 15-24 - Mark double chain before removing (e.g. with paint, arrow pointing in engine running direction). Note: Do not mark the chain with a center punch or any similar means that could scratch or deface the metal surface! Camshaft for cylinders 1, 3 and 5 - First remove bearing caps 1 and 7.
Page 610 Valve train, servicing Page 15 of 22 15-25 - Loosen bearing caps 2 and 6 alternately and diagonally. Installing - Oil running surfaces of both camshafts. Note: Observe engine running direction markings on double chain! When installing the camshafts the recess for the camshaft sprockets -arrows- must be at top.
Page 611 Valve train, servicing Page 16 of 22 15-26 - Install bearing cap 4 and tighten to: 20 Nm (15 ft lb). - Clean sealing surfaces of cover for camshaft sprockets and cylinder head. - Remove old sealant from 3 mm holes in cylinder head gasket -arrows-.
Page 612 Valve train, servicing Page 17 of 22 15-27 Note: If the chain tensioner has been pulled apart, bleed chain tensioner before installing Page 13-7 Fig. 2. When new lifters have been installed, the engine must not be started for approx. 30 minutes.
Page 613 Valve train, servicing Page 18 of 22 15-28 Hydraulic lifters, checking Note: Replace defective lifter(s) as complete assemblies (can not be adjusted or repaired). Irregular valve noises when starting engine are normal. - Start engine and run until radiator cooling fan comes on once.
Page 614 Valve train, servicing Page 19 of 22 15-29 Valve guides, checking - Insert new valve into guide until end of valve stem is flush with end of guide. Due to the slight difference in stem dimensions, make sure that only an intake valve is used in the intake guide and an exhaust valve in the exhaust guide.
Page 615 Valve train, servicing Page 20 of 22 15-30 Valve guides, replacing - Clean and check cylinder head. Cylinder heads in which the valve seats can no longer be reworked, or cylinder heads which have already been machined to the minimum dimension (height) Page 15-15 , item 7 , or already have...
Page 616 Valve train, servicing Page 21 of 22 15-31 Valve stem seals, replacing With cylinder head installed - Remove camshafts Page 15-23 - Remove lifters (do not interchange) and store with the contact surface downward. - Remove spark plugs. - Set piston of appropriate cylinder to "bottom dead center".
Page 617 Valve train, servicing Page 22 of 22 15-32 - Install assembly tool 2036 and adjust mountings to height of studs. - Screw compressed air hose VW 653/3 into spark plug thread and apply a continuous pressure of 6 bar (minimum). - Remove valve springs using lever VW 541/1A and press tool VW 541/5.
Page 618 Lubrication system, component removal and installation Page 1 of 9 17-1 Lubrication system, component removal and installation Notes: When repairing an engine, metal shavings or large quantities of small metal particles (for example, caused by partial seizure of crankshaft and connecting rod bearings) are found in engine oil;...
Page 619 Lubrication system, component removal and installation Page 2 of 9 17-2 Engine oil specifications: The following terms must appear on the oil container or in combination with other designations: VW 502 00 or VW500 00 or VW501 01 ACEA A2 or ACEA A3 API-SJ or API-SL Engine oils are graded according to viscosity.
Page 620 Lubrication system, component removal and installation Page 3 of 9 17-3 1 - 10 Nm (7 ft 2 - Oil pump drive cover 3 - O-ring Always replace Lubricate before installing 4 - Oil pump drive 5 - Intermediate shaft 6 - Thrust washer 7 - 10 Nm (7 ft...
Page 621 Lubrication system, component removal and installation Page 4 of 9 17-4 9 - 25 Nm (18 ft lb) 10 - 10 Nm (7 ft Always replace Install with locking fluid "D6" 11 - Oil drain plug 30 Nm (22 ft lb) Replace if leaking.
Page 622 Lubrication system, component removal and installation Page 5 of 9 Removing installing Fig. 1 Opening pressure: 2.0 bar See note Page 17-1 14 - 15 Nm (11 ft lb) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 623 Lubrication system, component removal and installation Page 6 of 9 17-5 15 - Gasket Replace damaged Before installing gasket coat sump flange cylinder block flange with "D2" 16 - Sump Clean sealing surface before installing 17 - Oil cooler Coat contact area to flange,...
Page 624 Lubrication system, component removal and installation Page 7 of 9 25 Nm (18 ft lb) 19 - Gasket Always replace Note installation position before installing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 625 Lubrication system, component removal and installation Page 8 of 9 17-6 20 - Oil filter housing Disassembling assembling Page 17-8 21 - Dipstick The oil level must not be above the max. mark on dipstick! 22 - Guide tube Secure bolt to inlet manifold...
Page 626 Lubrication system, component removal and installation Page 9 of 9 17-7 Fig. 1 Removing and installing oil spray jet Note: Oil spray jets are installed in main bearings 2 ... 7. Crankshaft removed - Remove with 4 mm diameter punch. - Install by hand with a 6 mm diameter punch -arrow-.
Page 627 Oil filter housing, disassembling and assembling Page 1 of 8 17-8 Oil filter housing, disassembling assembling 1 - Gasket Always replace Note installed position Oil before installing 2 - 0.3 bar oil pressure switch -F22- 20 Nm (15 ft Brown Wiring: blue/black Checking...
Page 628 Oil filter housing, disassembling and assembling Page 2 of 8 17-9 5 - Oil filter element Observe change intervals With by- pass valve Opening pressure: 2.0 bar Clip into oil filter lower section before installing 6 - O-ring Always replace Lubricate before installing...
Page 629 Oil filter housing, disassembling and assembling Page 3 of 8 17-10 10 - 1.4 bar oil pressure switch - 25 Nm (18 ft lb) Black Wiring: yellow Checking Page 17-14 If sealing ring is leaking nip open replace. Engine oil temperature sensor -G8- 10 Nm (7...
Page 630 Oil filter housing, disassembling and assembling Page 4 of 8 17-11 Oil pump, disassembling assembling 1 - Drive shaft For oil pump drive 2 - Oil pump housing 3 - 25 Nm (18 ft lb) 4 - Gears Checking backlash Fig.
Page 631 Oil filter housing, disassembling and assembling Page 5 of 8 17-12 6 - 10 Nm (7 ft Always replace Install with locking fluid "D6" 7 - Oil pressure pipe Coat cylinder block and oil pump housing with AMV188 001 02 8 - 10 Nm (7 ft 9 - O ring Replace...
Page 632 Oil filter housing, disassembling and assembling Page 6 of 8 17-13 Fig. 1 Checking oil pump backlash Wear limit: 0.20 mm Fig. 2 Checking oil pump axial clearance Wear limit: 0.10 mm http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 633 Oil filter housing, disassembling and assembling Page 7 of 8 17-14 Oil pressure and oil pressure switch, checking Note: To check and service the optical and acoustic oil pressure warning see the wiring diagram. - Remove 0.3 bar oil pressure switch -F22- (brown insulation) and screw into the tester.
Page 634 Oil filter housing, disassembling and assembling Page 8 of 8 17-15 - Connect diode test lamp to 1.4 bar oil pressure switch -F1- (black insulation) -B-. At 1.21.6 bar the LED must light up. - If LED does not light up, replace oil pressure switch -F1-.
Page 635 Cooling system, component removal and installation Page 1 of 19 19-1 Cooling system, component removal and installation Note: When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Hoses are secured with spring-type clips. In case of repair only use spring-type clips.
Page 636 Cooling system, component removal and installation Page 2 of 19 19-2 Cooling system component layout (body side) 1 - 10 Nm (7 ft 2 - Cover 3 - Lock carrier 4 - Air ducting 5 - Bracket 6 - Engine coolant radiator Removing...
Page 637 Cooling system, component removal and installation Page 3 of 19 19-3 10 - Guide ring Note installed position Mounted on fan ring (item 12) using clips 11 - Additional Removing installing Page 19-15 12 - Fan ring 13 - Connector 14 - Radiator cooling Removing...
Page 638 Cooling system, component removal and installation Page 4 of 19 Switching temperatures: Stage 1 92...97 C off: 84...91 C Stage 2 99...105 off: 91...98 C http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 639 Cooling system, component removal and installation Page 5 of 19 19-4 16 - Lower coolant hose thermostat housing Page 19- , item 19 17 - Connection 18 - O-ring Alway replace 19 - Retaining clip Make sure that it is seated securely 20 - Upper...
Page 640 Cooling system, component removal and installation Page 6 of 19 19-5 Cooling system, component layout (engine side) 1 - 25 Nm(18 ft lb) loosen tighten use VAG 1590 Modify water pump wrench 1590 Fig. 1 2 - Pulley coolant circulation pump 3 - 20 Nm(15 ft lb)
Page 641 Cooling system, component removal and installation Page 7 of 19 Always replace 6 - Throttle body 7 - From cylinder head http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 642 Cooling system, component removal and installation Page 8 of 19 19-6 8 - Continued coolant circulation pump - V51- Checking Page 19-21 Secured with bracket to the camshaft sprocket cover Page 15- , item 9 - Connector 10 - Retaining clip Make sure that...
Page 643 Cooling system, component removal and installation Page 9 of 19 Checking 12 - From heat exchanger 13 - To heat exchanger http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 644 Cooling system, component removal and installation Page 10 of 19 19-7 14 - Cap Check with VAG 1274 and 1274/4 Test pressure: 1.3...1.5 15 - Cover 16 - 10 Nm (7 ft 17 - Expansion tank 18 - Upper coolant hose To top off radiator...
Page 645 Cooling system, component removal and installation Page 11 of 19 transmission Repair Manual, 4 Spd. Automatic Transmission, Repair Group 37; Removing and installing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 646 Cooling system, component removal and installation Page 12 of 19 19-8 21 - Thermostat housing Disassembling assembling Page 19-10 22 - Coolant hose 23 - Oil cooler Removing installing Page 17-5 item 17 24 - To cylinder block 25 - Drain screw 10 Nm (7 ft lb)
Page 647 Cooling system, component removal and installation Page 13 of 19 19-9 Fig. 1 Modifying coolant pump wrench VAG 1590 - Due to the modified bolts for securing the coolant pump pulley, file the three corners which have already been rounded off by: a = 1 mm. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 648 Cooling system, component removal and installation Page 14 of 19 19-10 Coolant thermostat housing, disassembling assembling Note: Connecting the coolant hoses to thermostat housing Page 19-5 1 - Thermostat housing 2 - 10 Nm (7 ft 3 - Coolant thermostat Checking: submerge thermostat...
Page 649 Cooling system, component removal and installation Page 15 of 19 19-11 5 - 10 Nm (7 ft 6 - O-Ring Always replace 7 - Connection 8 - Plug vehicles without A/C Cut- Thermal switch - F163- and Third Speed Coolant Control Thermal switch -...
Page 650 Cooling system, component removal and installation Page 16 of 19 19-12 9 - After-Run Coolant Fan Control Thermal switch -F87- with Engine Coolant Temperature sensor -G2- Yellow, 4-pin Checking Page 19-21 Switching temperatures: 101...107 off: 94...100 Engine Coolant Temperature sensor - G62- Blue, 2- Motronic...
Page 651 Cooling system, component removal and installation Page 17 of 19 seated securely http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 652 Cooling system, component removal and installation Page 18 of 19 19-13 Cooling system, draining and filling Draining - Remove cap from coolant expansion tank. - Remove drain screw from coolant line Page 19-8 , item 25 Filling Note: The cooling system is filled all-year-round with a mixture of water and anti-freeze and corrosion protection agent G 11.
Page 653 Cooling system, component removal and installation Page 19 of 19 19-14 Recommended mixture ratios: Freezing Antifreeze Water protection percentage down to: 6.5 ltr. -25 C ltr. 5.0 ltr. -35 C ltr. The amount of anti-freeze must not exceed 60 %; freezing protection and cooling efficiency will decrease if anti-freeze percentage is too high.
Page 654 Radiator and radiator fan, removing and installing Page 1 of 7 19-15 Radiator and radiator fan, removing and installing Removing - Drain coolant Page 19-13 - Remove coolant hoses off radiator. - Disconnect thermal switch and radiator coolant fan connectors. - Remove radiator mounting bolts.
Page 655 Radiator and radiator fan, removing and installing Page 2 of 7 19-16 Additional information and removal work for vehicles with A/C CAUTION! The A/C refrigerant circuit must not be opened. Note: To prevent damage to the condensor, refrigerant lines and hoses, make sure that the lines and hoses are not stretched, kinked or bent.
Page 656 Radiator and radiator fan, removing and installing Page 3 of 7 19-17 Coolant pump, removing and installing Removing - Switch off ignition. - Disconnect battery ground cable Note: Obtain the radio anti-theft code from the customer before disconnecting the battery. - Disconnect exhaust pipe from the three-way catalyst flange Page 26-2...
Page 657 Radiator and radiator fan, removing and installing Page 4 of 7 19-18 - Disconnect ignition wires out of ignition coil and unclip from the ignition wiring guide -2-. - Remove the ignition wiring guide -2-. - Disconnect vacuum hose between intake manifold upper section and fuel pressure regulator - Remove Intake Air Temperature...
Page 658 Radiator and radiator fan, removing and installing Page 5 of 7 19-19 - Detach engine from front engine/trans mount from above. - Carefully lift engine. - Remove coolant pump pulley (use VAG 1590 to loosen and tighten the mounting bolt). Note: If necessary modify water pump wrench VAG 1590...
Page 659 Radiator and radiator fan, removing and installing Page 6 of 7 19-20 - Align engine mounts stress-free by rocking engine assembly. - First tighten assembly mountings front and right- rear, then tighten left-rear assembly mounting, Page 10-11 Repair Manual, 2.8 Liter VR6 2V Fuel Injection &...
Page 660 Radiator and radiator fan, removing and installing Page 7 of 7 19-21 Coolant after-run system, checking - Remove cover above thermostat housing. - Switch on ignition and then switch off again. - Disconnect 4-pin harness connector from After Run Coolant Fan Control Thermal switch -F87 with Engine Coolant Temperature sensor -G2 yellow-.
Page 661 Fuel supply system components, removing and installing Page 1 of 26 20-1 Fuel supply system components, removing and installing Notes: Hose connections are secured with either screw, clamp or spring-type clips. Always replace clamp-type clips with screw or spring type clips. Fuel hoses in engine compartment must be secured with spring type clips.
Page 662 Fuel supply system components, removing and installing Page 2 of 26 20-2 Fuel tank assembly and fuel filter, removing and installing Front wheel drive vehicles 1 - Cap 2 - Seal Replace damaged 3 - Retaining ring 4 - Rubber 5 - Ground connection 6 - O-ring...
Page 663 Fuel supply system components, removing and installing Page 3 of 26 20-3 9 - Return line Blue From fuel rail 10 - Union nut Remove install with 3217 11 - Flange Note installed position on fuel tank Page 20- Fig. 1 12 - Supply hose 13 - Sealing...
Page 664 Fuel supply system components, removing and installing Page 4 of 26 20-4 15 - Fuel level sensor 16 - Fuel pump Removing installing Page 20-13 Fuel pump, checking Page 20-16 17 - Securing strap Note differing lengths 18 - Bracket securing straps 19 - 25 Nm (18...
Page 665 Fuel supply system components, removing and installing Page 5 of 26 20-5 21 - Supply line Black To fuel rail 22 - Fuel filter Installed position: Arrow points in direction of flow 23 - Retaining clip 24 - Vent hose Fuel tank vent shown:...
Page 666 Fuel supply system components, removing and installing Page 6 of 26 20-6 26 - 10 Nm (7 ft 27 - Vent line To EVAP canister Page 20-21 item 1 28 - Gravity valve remove valve, unclip upward out of filler neck Check valve for flow...
Page 667 Fuel supply system components, removing and installing Page 7 of 26 20-7 Fig. 1 Installed position of fuel pump flange assembly on fuel tank Marking on the flange must align with marking on the fuel tank. Fig. 2 Checking vent valve Lever in rest position: Closed Lever pushed in direction of arrow: Open...
Page 668 Fuel supply system components, removing and installing Page 8 of 26 20-8 Fig. 3 Fuel tank venting for the Wagon http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 669 Fuel supply system components, removing and installing Page 9 of 26 20-9 Safety precautions when working on the fuel supply system When removing and installing the fuel level sensor or fuel pump (fuel delivery unit) from a full or partially filled fuel tank the following must be observed: Before starting work, switch on exhaust extraction system and place an extraction...
Page 670 Fuel supply system components, removing and installing Page 10 of 26 20-10 Rules for cleanliness When working on the fuel supply and injection system, observe the following "5 rules": Thoroughly clean all unions and adjacent areas before disconnecting. Place parts that have been removed on a clean surface and cover.
Page 671 Fuel supply system components, removing and installing Page 11 of 26 20-11 Throttle cable, adjusting - Remove spark plug connectors and ignition wires. - Remove ignition wire guides -1- and - - Remove cover above intake manifold upper section -3-. Vehicles with manual transmission - Adjust throttle cable by moving the retaining clip- arrow- at the support...
Page 672 Fuel supply system components, removing and installing Page 12 of 26 20-12 Vehicles with automatic transmission - Clamp distance piece -1-, a = 15 mm, between accelerator pedal -2- and stop -3- and hold accelerator pedal in this position. - Fully open throttle by pulling on the outer cable and secure in this position using the retaining clip - arrow-.
Page 673 Fuel supply system components, removing and installing Page 13 of 26 20-13 - Connect Fluke 83 multimeter to kick- down switch using jumper wires from VW 1594 adaptor kit. - Check resistance at switch. Specification: - Slowly move accelerator pedal in direction of wide open throttle.
Page 674 Fuel supply system components, removing and installing Page 14 of 26 20-14 Fuel pump assembly, removing and installing Removing - Observe safety precautions Page 20-9 - Switch off ignition. - Disconnect battery ground cable. Note: Obtain the radio anti-theft code from the customer before disconnecting the battery.
Page 675 Fuel supply system components, removing and installing Page 15 of 26 20-15 - Disconnect 4-pin connector and supply and return lines from the fuel pump assembly at the flange. - Loosen the flange nut using 3217. - Remove the flange nut and seal from the fuel tank opening.
Page 676 Fuel supply system components, removing and installing Page 16 of 26 20-16 Fuel pumps, checking Battery voltage OK. Fuse No.18 0K. - Switch on ignition. Fuel pump must run briefly (and be audible). If the fuel pumps do not run: - Switch off ignition.
Page 677 Fuel supply system components, removing and installing Page 17 of 26 20-17 - Connect remote control VAG 1348/3A using adaptor cable VAG 1348/3-2 between terminal 4 and battery positive (+). - Operate remote control. If fuel pump runs: - Re-install fuel pump relay. Repair Manual, 2.8 Liter VR6 2V Fuel Injection &...
Page 678 Fuel supply system components, removing and installing Page 18 of 26 20-18 LED lights up (voltage supply OK.): - Loosen flange nut using 3217. - Check if the wiring between harness and fuel pump assembly is connected. If no open circuit can be found: - Replace fuel pump Page 20-13 Delivery rate, checking...
Page 679 Fuel supply system components, removing and installing Page 19 of 26 20-19 - Push hose adaptor VAG 1318/1 onto pressure gauge adaptor VAG 1318/11 and hold in measuring container. - Open pressure gauge shut-off (lever in direction of flow - position -A-). - Operate remote control VAG 1348/3A and slowly close shut-off lever, until the gauge indicates 4 bar.
Page 680 Fuel supply system components, removing and installing Page 20 of 26 20-20 Fuel pump check valve, checking Remote control VAG 1348/3A connected Pressure gauge VAG 1318 connected Note: With this check the fuel supply line connections from the fuel pump to the point at which the pressure gauge VAG 1318 is connected will be checked for leaks at the same time.
Page 681 Fuel supply system components, removing and installing Page 21 of 26 20-21 EVAP system components, removing and installing 1 - Vent line From gravity valve on fuel tank Page 20-6 item 27 2 - Harness connector 2-pin 3 - EVAP canister purge regulator...
Page 682 Fuel supply system components, removing and installing Page 22 of 26 Fuel Injection & Ignition, Repair Group 01; Checking http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 683 Fuel supply system components, removing and installing Page 23 of 26 20-22 4 - Retaining ring 5 - Bracket On air cleaner lower section 6 - Intake manifold upper section 7 - Vent hose 8 - From crankcase breather valve 9 - 10 Nm (7 ft 10 - EVAP canister...
Page 684 Fuel supply system components, removing and installing Page 24 of 26 20-23 Fuel tank ventilation, checking Uses special tools, testers and resources Hand vacuum pump US 8026 ((VAG 1390) Vacuum tester VAG 1397A (the VAG 1368 tester shown in the illustration is not intended for the North American market) Test Conditions:...
Page 685 Fuel supply system components, removing and installing Page 25 of 26 20-24 - Place vacuum pressure tester in position B. - Activate hand vacuum pump several times. Pressure should not build up. If pressure builds - Check vent fitting -5- on EVAP canister -4- for contamination, clean if necessary - Check EVAP canister purge regulator valve N80- -6- for continuity, replace if necessary.
Page 686 Fuel supply system components, removing and installing Page 26 of 26 20-25 - Activate hand vacuum pump several times. Vacuum should not build up Note: With low fuel levels in the fuel tank, the hand vacuum pump must be operated at least 20...30 times.
Page 687 Exhaust system components, removing and installing Page 1 of 16 26-1 Exhaust system components, removing and installing Front wheel drive vehicles Notes: After working on the exhaust system, make sure that the system is not under stress, and it has sufficient clearance from the body. If necessary, loosen the double and single clamps and align the muffler and exhaust pipes so that sufficient clearance is maintained from...
Page 688 Exhaust system components, removing and installing Page 2 of 16 26-2 Exhaust manifold, front exhaust pipe and three-way catalyst assembly, component layout 1 - Heat shield 2 - Lifting eye 3 - 25 Nm (18 ft lb) 4 - Exhaust manifold 2 part http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 689 Exhaust system components, removing and installing Page 3 of 16 26-3 5 - Connector 4 pin Heated Oxygen sensor Oxygen sensor heater Secured to the right rear engine and trans mount Check Heated Oxygen sensor basic heater Voltage Repair Manual, 2.8 Liter VR6 2V Fuel Injection &...
Page 690 Exhaust system components, removing and installing Page 4 of 16 26-4 6 - Heated Oxygen sensor - G39- 50 Nm (37 ft lb) Only grease threads with "G5"; do allow "G5" to get into the slots on the sensor Checking 7 - Three-way catalyst 8 - To front...
Page 691 Exhaust system components, removing and installing Page 5 of 16 26-5 Muffler system mountings, component layout Note: Align the exhaust system longitudinally so that the dimensions -a- and -b- are maintained. 1 - Mount Note installation position 2 - 25 Nm(18 ft lb) 3 - Center muffler...
Page 692 Exhaust system components, removing and installing Page 6 of 16 26-6 8 - Marking clamp Three times circumference Distance clamp/marking item 11 9 - Separating point To allow individual exhaust component replacements When replacing center muffler item 3 Marked by three impressions circumference...
Page 693 Exhaust system components, removing and installing Page 7 of 16 supplied separately. To make connection, a repair connecting pipe item 14 and two clamps are supplied. - Cut through connecting pipe with a hacksaw at right angles at separating point. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 694 Exhaust system components, removing and installing Page 8 of 16 26-7 10 - Separating point To allow individual exhaust component replacements When replacing the rear muffler item 5 Marked by three impressions circumference of connecting pipe production, the center and rear muffler are one part.
Page 695 Exhaust system components, removing and installing Page 9 of 16 through connecting pipe with a hacksaw at right angles at separating point. 11 - Dimension -b- = approx. 5 12 - Marking Three times circumference http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 696 Exhaust system components, removing and installing Page 10 of 16 26-8 13 - 14Dim. -a- = approx. 5 mm 15 - Repair connecting pipe 16 - Sheet metal nut Must be screwed- on/off 17 - Heat shield 18 - From three-way catalyst Page...
Page 697 Exhaust system components, removing and installing Page 11 of 16 26-9 Exhaust gas recirculation system Notes: The function and control of the Exhaust Gas Recirculation (EGR) system is checked by the On Board Diagnostic system of the Motronic Engine Control Module (ECM) -J220-. Repair Manual, 2.8 Liter VR6 2V Fuel Injection &...
Page 698 Exhaust system components, removing and installing Page 12 of 16 26-10 1 - EGR valve Checking Page 26-12 2 - EGR Temperature sensor - G98-* 20 Nm (15 ft lb) Checking Page 26-12 3 - Pipe exhaust gas inlet 4 - EGR valve -N18-*/** Two-way valve...
Page 699 Exhaust system components, removing and installing Page 13 of 16 26-11 7 - Connector 2-pin For EGR Temperature sensor - G98- 8 - Pipe For exhaust gas outlet http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 700 Exhaust system components, removing and installing Page 14 of 16 26-12 Exhaust Gas Recirculation (EGR) valve, checking Note: Check using VAG 1551 Scan Tool in "Read measuring value block" function, perform check during idle. Vacuum lines and hose connections free of leaks. Vacuum lines not blocked or kinked.
Page 701 Exhaust system components, removing and installing Page 15 of 16 26-13 Display will appear as shown: (1...4 = Read measuring value block 2 Display zones) 1 2 3 4 Note: If the display remains blank, see Scan Tool operating instructions - Pull vacuum hose off EGR valve.
Page 702 Exhaust system components, removing and installing Page 16 of 16 26-14 - Input 06 for "End output" and confirm with If the temperature value does not change: Repair Manual, 2.8 Liter VR6 2V Fuel Injection & Ignition, Repair Group 01; Check activation of EGR valve -N18- EGR valve must click during the electrical check:...
Page 703 Secondary Air Injection system, function Page 1 of 15 26-15 Secondary Air Injection system, function The Secondary Air Injection system blows in air behind the exhaust valve for 65 seconds during the cold start (+15 C ... +35 C engine coolant temperature). This produces an Oxygen rich exhaust gas, causes afterburning and reduces the heat-up time for the three-way catalyst.
Page 704 Secondary Air Injection system, function Page 2 of 15 26-16 Secondary Air Injection system components, removing and installing Notes: Secondary Air Injection pump relay - J299- * Page 26-20 Fig. 1 Repair Manual, 2.8 Liter VR6 2V Fuel Injection & Ignition, Repair Group 01;...
Page 705 Secondary Air Injection system, function Page 3 of 15 Removing installing Page 26-24 2 - Lifting eye On left side of cylinder head http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 706 Secondary Air Injection system, function Page 4 of 15 26-17 3 - Bracket Secondary Injection pump motor item 1 and Secondary Injection solenoid valve item 4 - 25 Nm(18 ft lb) 5 - Connector 2-pin 6 - 10 Nm (7 ft ;lb) 7 - Secondary Injection...
Page 707 Secondary Air Injection system, function Page 5 of 15 To intake manifold upper section or manifold connector http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 708 Secondary Air Injection system, function Page 6 of 15 26-18 9 - Vacuum hose From Secondary Injection solenoid valve, (item 7 ) to Combi- valve, (item 13 ) 10 - Intake hose 11 - Pressure hose Make sure tight (leak- free) connection 12 - To Air...
Page 709 Secondary Air Injection system, function Page 7 of 15 Injection port cylinder head http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 710 Secondary Air Injection system, function Page 8 of 15 26-19 Fig. 1 Secondary Air Injection pump relay -J299- with fuse -arrow- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 711 Secondary Air Injection system, function Page 9 of 15 26-20 Combi-valve, checking - Remove pressure hose from combi-valve. - Pull vacuum hose off Secondary Air Injection solenoid valve -N112-. - Connect hand vacuum pump US 8026 to vacuum hose -1- to combi-valve. Note: Do not use compressed air during the following check!
Page 712 Secondary Air Injection system, function Page 10 of 15 26-21 Secondary Air Injection pump motor, checking Fuse -arrow- on Secondary Air Injection pump relay -J299- OK. Engine oil temperature 15 ... 85 C - Remove pressure hose from combi- valve and route upward. - Start engine and let idle.
Page 713 Secondary Air Injection system, function Page 11 of 15 26-22 - Replace Secondary Air Injection pump motor - V101-. If LED does not light up: - Reconnect 2-pin harness connector. Repair Manual, 2.8 Liter VR6 2V Fuel Injection & Ignition, Repair Group 01; Check activation of Secondary Air Injection pump motor.
Page 714 Secondary Air Injection system, function Page 12 of 15 26-23 Secondary Air Injection solenoid valve, checking Engine oil temperature 15 ... 85 C - Pull vacuum hose off combi-valve and route upward. - Start engine and let idle. After approx. 20 seconds the Secondary Air Injection pump motor runs for approx.
Page 715 Secondary Air Injection system, function Page 13 of 15 26-24 Repair Manual, 2.8 Liter VR6 2V Fuel Injection & Ignition, Repair Group 01; Check Secondary Air Injection solenoid valve activation. Electrical checks. Secondary Air Injection solenoid valve cannot be observed to switch during the electrical check: - Check DTC memory for Secondary Air Injection pump relay -J299- stored code, also reference the wiring diagram.
Page 716 Secondary Air Injection system, function Page 14 of 15 26-25 Combi-valve and Secondary Air Injection pump motor, removing and installing Removing - Switch off ignition. - Disconnect battery ground cable. Note: Obtain radio anti-theft code from customer before disconnecting the battery. Vehicles with A/C - Remove retaining clamp(s) from refrigerant lines.
Page 717 Secondary Air Injection system, function Page 15 of 15 26-26 Notes: The opening of the refrigerant circuit can only be carried out in workshops, which have trained personnel and the necessary range of tools and workshop equipment. To prevent damage to the condenser and refrigerant lines and hoses, make sure that the lines and hoses are not stretched, kinked or bent.
Page 720 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995 01 - On Board Diagnostic (OBD) On Board Diagnostic Function Technical data VAG 1551 Scan Tool (ST), connecting and selecting function Engine Control Module (ECM) coding, checking Diagnostic Trouble Code (DTC) memory, checking ((VAG 1551 function 02) Diagnostic Trouble Code (DTC) table Diagnostic Trouble Code (DTC) memory, erasing ((VAG 1551 function 05)
Page 721 Intake air system, checking for leaks (outside air) Intake air preheating, checking 28 - Ignition/Glow plug system Motronic fuel injection and ignition system Motronic ignition system, servicing Safety precautions Technical data, spark plugs Distributor, removing and installing Ignition timing control, checking Camshaft Position (CMP) sensor, checking Knock sensor, checking Ignition coil, checking...
Page 722 On Board Diagnostic Page 1 of 56 01-1 On Board Diagnostic Function The Motronic Engine Control Module (ECM) J220 is equipped with Diagnostic Trouble Code (DTC) memory. Malfunctions in monitored sensors or components are stored in DTC memory along with an indication of the type of malfunction. Check DTC memory and display stored Diagnostic Trouble Codes (DTC) by initiating the On Board Diagnostic (OBD) program...
Page 723 On Board Diagnostic Page 2 of 56 01-2 Technical data Equipped with: DTC memory: Non-volatile memory and volatile memory1 Rapid data transfer Will be cancelled after 40th engine start if malfunction has not occurred again. Engine Control Module (ECM) identification Page 01-4 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 724 On Board Diagnostic Page 3 of 56 01-3 Engine Control Module (ECM) functions Note: The Motronic ECM is equipped with various functions. Some functions can be carried out with ignition switched on or with engine running. The following table details the prerequisites for carrying out the individual functions.
Page 725 On Board Diagnostic Page 4 of 56 01-4 VAG 1551 Scan Tool (ST), connecting and selecting function Special tools, testers and auxiliary items VAG 1551 scan tool with cable VAG 1551/3 Note: The VAG 1552 vehicle system tester can be used instead of the VAG 1551 scan tool, however a print-out is not possible.
Page 726 On Board Diagnostic Page 5 of 56 01-5 Depending upon the desired function: - Switch ignition on - Start engine. Engine Control Module (ECM) functions table, page 01-3 Note: If the display is not as indicated in the work sequence: VAG 1551 scan tool operating instructions If due to an input malfunction "Error in communication link"...
Page 727 On Board Diagnostic Page 6 of 56 01-6 ECM identification and coding indicated 037 906 258K Engine 20Q 400101-S on display, e.g.: Coding 2 AG 037 906 258K ECM Part No. (for latest version see parts catalog microfiche) Engine 20Q = 2.0 liter cross-flow engine 400101-S = Program level number and version...
Page 728 On Board Diagnostic Page 7 of 56 01-7 Engine Control Module (ECM) coding, checking Special tools, testers and auxiliary items VAG 1598 test box Hand multimeter VAG 1526 or multimeter VAG 1715 VW 1594 connector test kit Wiring diagram Work sequence - Connect VAG 1598 test box to engine control module wiring harness.
Page 729 On Board Diagnostic Page 8 of 56 01-8 If the specifications are not attained: - Locate and repair open circuit using wiring diagram. Note: Incorrect coding leads to: Engine running malfunctions Increased fuel consumption Increased emissions Malfunctions stored in DTC memory that are not actually present Reduced transmission life http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 730 On Board Diagnostic Page 9 of 56 01-9 Diagnostic Trouble Code (DTC) memory, checking ((VAG 1551 function 02) - Connect VAG 1551 scan tool and insert "Engine Electronics" address word 01; selection is carried out with engine idling page 01-4 If engine does not start: - Operate starter for approx.
Page 731 On Board Diagnostic Page 10 of 56 01-10 If one or more DTCs are stored: The malfunctions stored will be displayed and printed out one after the other. Indicated on display Rapid data transfer HELP Select function XX If no DTC is stored: - Press button.
Page 732 On Board Diagnostic Page 11 of 56 01-11 Diagnostic Trouble Code (DTC) table Note: The DTC table is listed according to the 5-digit diagnostic trouble code on the left. Before replacing components indicated as malfunctioning, check the wiring and connectors to these components as well as the ground connections using the wiring diagrams.
Page 733 On Board Diagnostic Page 12 of 56 01-12 VAG 1551 Possible cause Possible effect Corrective action print-out No DTC If no malfunction has been detected: malfunction not recognized by On recognized Board Diagnostic program 00281 Vehicle speed sensor-G68 Incorrect No signal from Speedometer not - Check signal from signal...
Page 734 On Board Diagnostic Page 13 of 56 01-13 VAG 1551 print- Possible cause Possible Corrective action effect 00513 Engine Speed Sensor-G28 Incorrect Gap between speed Engine will - Check G28 for tight signal sensor and sender wheel not start fit, metal particles too large page 24-11 , item...
Page 735 On Board Diagnostic Page 14 of 56 01-14 VAG 1551 print- Possible cause Possible effect Corrective action 00515 Camshaft Pos. Sensor-G40 Open/Short Camshaft Position High fuel - Check G40 circuit to B+ (CMP) sensor G40 consumption page 28-15 faulty Short to - Check distributor Wiring open circuit Reduced output...
Page 736 On Board Diagnostic Page 15 of 56 01-15 VAG 1551 print- Possible cause Possible effect Corrective action 00518 Throttle Pos. Sensor-G69 Short to Ground Wiring open circuit Hard load - Check G69 change page 24-46 Wire has short to ground Throttle position sensor G69 faulty Open/Short circuit...
Page 737 On Board Diagnostic Page 16 of 56 01-16 VAG 1551 print- Possible cause Possible effect Corrective action 00522 Engine Coolant Temp.Sensor- Short to Wire has short to - Check G62 Poor cold starting Ground ground page 24- Engine Coolant Poor hot starting Temperature (ECT) sensor G62 faulty Open/Short...
Page 738 On Board Diagnostic Page 17 of 56 01-17 VAG 1551 print- Possible cause Possible effect Corrective action 00524 Knock Sensor 1- Open/short Wiring open circuit Reduced - Check G61 circuit to or short to ground performance page 28-17 Ground Increased fuel Knock sensor G61 - Replace G61 consumption...
Page 739 On Board Diagnostic Page 18 of 56 01-18 VAG 1551 Possible cause Possible effect Corrective action print-out 00525 Heated Oxygen Sensor-G39 No signal Wiring open circuit No oxygen - Check oxygen sensor probe sensor and oxygen sensor control control page 24-30 Oxygen sensor - Check oxygen sensor heating faulty...
Page 740 On Board Diagnostic Page 19 of 56 01-19 VAG 1551 print- Possible cause Possible effect Corrective action 00527 Intake Air Temp.Sensor- Short to Wire has short to - Check G72 Poor hot starting Ground ground page 24- Intake Air Temperature (IAT) sensor G72 faulty Open/Short Intake manifold...
Page 741 On Board Diagnostic Page 20 of 56 01-20 VAG 1551 Possible cause Possible Corrective action print-out effect 00532 Supply Voltage (B+) Signal too Battery positive Engine will - Check generator: high voltage (B+) not start exceeds 16.0 V Wiring diagrams, Electrical Wiring Diagrams, Troubleshooting and Component Locations binder...
Page 742 On Board Diagnostic Page 21 of 56 01-21 VAG 1551 Possible cause Possible effect Corrective action print-out 00537 Oxygen Sensor Control Control limit No oxygen - Check HO2S and Short to ground exceeded sensor control oxygen sensor (control at control page 24-30 limit) Control limit...
Page 743 On Board Diagnostic Page 22 of 56 01-22 VAG 1551 Possible cause Possible effect Corrective print-out action 00543 RPM upper Limit exceeded Signal too The governed speed of the Governed - Erase DTC high engine has been reached speed reduced memory (wrong gear selected, engine to 5000 RPM...
Page 744 On Board Diagnostic Page 23 of 56 01-23 VAG 1551 print-out Possible cause Possible Corrective action effect 00545 Engine/Trans.Electrical Connection Short to Ground Malfunction in Hard - Check wiring to automatic gear transmission: transmission changes Wiring diagrams, Wiring open Electrical Wiring Diagrams, circuit or short Troubleshooting and to ground...
Page 745 On Board Diagnostic Page 24 of 56 01-24 VAG 1551 Possible cause Possible effect Corrective action print-out 00549 Consumption Signal Short circuit Wire 51 from Multi-function - Locate and eliminate to B+ Motronic ECM J220 indicator open/short circuit using to instrument cluster display is wiring diagram: has open circuit or...
Page 746 On Board Diagnostic Page 25 of 56 01-25 VAG 1551 Possible cause Possible effect Corrective action print-out 00561 Mixture Adjustment Adaption Oxygen sensor control Engine running - Check HO2S and limit not faulty problems oxygen sensor reached control page 24- Adaption No oxygen - Check fuel...
Page 747 On Board Diagnostic Page 26 of 56 01-26 VAG 1551 Possible cause Possible Corrective action print-out effect 00585 Temp.Sensor -G98 Short to Wire to temperature sensor Rough - Check G98: Ground has connection to vehicle idle ground Repair Manual, 2.0 Liter General, Engine, Repair Group 26 00586...
Page 748 On Board Diagnostic Page 27 of 56 01-27 VAG 1551 print-out Possible cause Possible Corrective action effect 00638 Engine/Trans.Electrical Connection 2 Short to Ground Wiring open circuit Hard - Check wiring to or short to ground gear automatic changes transmission: Wiring diagrams, Malfunction in Electrical Wiring...
Page 749 On Board Diagnostic Page 28 of 56 01-28 VAG 1551 print- Possible cause Possible Corrective action effect 00640 Heated Oxygen Sensor Relay- J278 Short circuit to Wire has short circuit No oxygen - Check J278 using to positive sensor output Diagnostic Test control Mode page 01-39...
Page 750 On Board Diagnostic Page 29 of 56 01-29 VAG 1551 print- Possible cause Possible Corrective action effect 01025 Malfunction Indicator Lamp Faulty Short circuit to Wire has short - Check wiring to MIL None circuit to positive using wiring diagram: Open/short Wiring diagrams, Electrical Malfunction...
Page 751 On Board Diagnostic Page 30 of 56 01-30 VAG 1551 print- Possible cause Possible Corrective action effect 01235 Secondary Air Inject.Solenoid Valve-N112 Short circuit to Wire has short - Check N112 using output None circuit to positive Diagnostic Test Mode page 01-39 - Check secondary air N112 faulty...
Page 752 On Board Diagnostic Page 31 of 56 01-31 VAG 1551 print- Possible cause Possible Corrective action effect 01242 Final Stage in Control Module No fault type Loose terminal to the Engine - Initiate output Diagnostic recognized final control elements will not Test Mode (DTM) page or Motronic ECM...
Page 753 On Board Diagnostic Page 32 of 56 01-32 VAG 1551 print- Possible cause Possible effect Corrective action 01249 Injector, Cyl.1- Open/short Wiring open circuit or Poor starting - Check fuel injectors circuit to Ground short to ground N30-N33 page 24- Fuel injector N30 Engine malfunctioning...
Page 754 On Board Diagnostic Page 33 of 56 01-33 VAG 1551 print-out Possible cause Possible effect Corrective action 01251 Injector, Cyl.3-N32 Open/Short circuit Injector Cyl.1 Injector Cyl.1 Injector Cyl.1 DTC to B+ DTC 01249 DTC 01249 01249 Short to Ground 01252 Injector, Cyl.4-N33 Open/Short circuit Injector Cyl.1...
Page 755 On Board Diagnostic Page 34 of 56 01-34 VAG 1551 print- Possible cause Possible Corrective action effect 01257 Idle Air Control Valve-N71 Short circuit to Wire has short Rough idle - Check N71 using output circuit to positive Diagnostic Test Mode (DTM) page 01-39 Idle Air Control...
Page 756 On Board Diagnostic Page 35 of 56 01-35 VAG 1551 print-out Possible cause Possible Corrective action effect 01264 Secondary Air Injection Pump Relay- J299 Short circuit to B+ Wire has short - Check J299 using output None circuit to positive Diagnostic Test Mode (DTM) page 01-39 - Check secondary air...
Page 757 On Board Diagnostic Page 36 of 56 01-36 VAG 1551 print- Possible cause Possible Corrective action effect 01265 EGR Vacuum Regulator Solenoid Valve- Open/short Wiring open - Check N18 using Rough idle circuit to circuit/short to ground output Diagnostic Test Ground Mode (DTM) page...
Page 758 On Board Diagnostic Page 37 of 56 01-37 Diagnostic Trouble Code (DTC) memory, erasing ((VAG 1551 function 05) Test conditions Malfunction(s) eliminated Work sequence - Carry out road test of at least 10 minutes duration. When doing this - Make sure that engine coolant temperature reaches at least 80 C (176 F) - Briefly depress accelerator pedal fully when engine speed is above 4600 RPM.
Page 759 On Board Diagnostic Page 38 of 56 01-38 Rapid data transfer HELP - Press button until all malfunctions Select function XX still stored have been displayed and the display reads as shown. - Press buttons -0- and -5- to select "Erase DTC Memory"...
Page 760 On Board Diagnostic Page 39 of 56 01-39 Output Diagnostic Test Mode (DTM) (VAG 1551 function 03) The output DTM actuates the following components in the stated sequence: 1 - Injector, Cyl. 1 N30 2 - Injector, Cyl. 2 N31 3 - Injector, Cyl.
Page 761 On Board Diagnostic Page 40 of 56 01-40 Test conditions Throttle Position (TP) sensor G69 OK Fuse 18 OK Test sequence - Connect VAG 1551 scan tool. Ignition switched on - Press buttons -0- and -1- to insert "Engine Electronics" address word 01 page 01-4 - Press -Q- button to confirm input.
Page 762 On Board Diagnostic Page 41 of 56 01-41 Indicated on display Output Diagnostic Test Mode Injector, Cyl.1-N30 If something different is displayed: - Press button repeatedly until "Select function XX" is displayed. - Again select "Output Diagnostic Test Mode" function 03 and confirm with - Q- button.
Page 763 On Board Diagnostic Page 42 of 56 01-42 Activate idle air control valve N71: - Press button. Indicated on display Output Diagnostic Test Mode Idle Air Control valve-N71 Idle air control valve must click, until switching to next component test by pressing button.
Page 764 On Board Diagnostic Page 43 of 56 01-43 - Check wiring between ECM connector and 2-pin connector terminal 2 for short to terminal 1 and/or chassis ground, according to wiring diagram. Connector terminal 2 to socket 27 Specification: (no continuity) - Also check wiring for short to battery positive voltage (B+).
Page 765 On Board Diagnostic Page 44 of 56 01-44 If valve does not open and close: - Disconnect 2-pin connector from valve and connect diode test lamp VAG 1527 to disconnected connector, using adapter cables from VW 1594 test kit. LED must flash If LED flashes: - Replace EVAP canister purge regulator valve N80.
Page 766 On Board Diagnostic Page 45 of 56 01-45 - Check wiring for open circuit between 2-pin connector terminal 2 and central electrics, according to wiring diagram. Wire resistance: Max. 1.5 - Check wiring between ECM connector and 2-pin connector terminal 1 for short to terminal 2 and/or chassis ground, according to wiring diagram.
Page 767 On Board Diagnostic Page 46 of 56 01-46 If relay does not click: - Switch ignition off. - Check HO2S relay J278 according to wiring diagram: Electrical Wiring Diagrams, Troubleshooting and Component Locations binder If an open circuit cannot be located: - Replace HO2S relay J278 or Motronic ECM J220 as necessary.
Page 768 On Board Diagnostic Page 47 of 56 01-47 If LED does not flash: - Switch ignition off. - Connect VAG 1598 test box to ECM wiring harness. - Check wiring for open circuit between test box and 2-pin connector terminal 2, according to wiring diagram.
Page 769 On Board Diagnostic Page 48 of 56 01-48 If no malfunction in wire is detected: - Reconnect connector to valve. - Replace Motronic ECM J220. - Press button. Indicated on display Output Diagnostic Test Mode Intake Manifold Change-over Valve-N156 - Ignore display. Activate Secondary Air Injection (AIR) pump relay J299: - Press...
Page 770 On Board Diagnostic Page 49 of 56 01-49 If LED does not light up: - Check fuse -3- on secondary air injection pump relay. - Connect VAG 1598 test box to ECM wiring harness. - Check wiring for open circuit between test box socket 50 and central electrics, according to wiring diagram.
Page 771 On Board Diagnostic Page 50 of 56 01-50 If AIR solenoid valve does not switch: - Disconnect 2-pin connector from AIR solenoid valve N112. - Connect diode test lamp VAG 1527 to disconnected harness connector, using adapter cables from VW 1594 test kit. LED must light up If LED lights up (voltage supply OK): - Replace AIR solenoid valve N112.
Page 772 On Board Diagnostic Page 51 of 56 - Switch ignition off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 773 On Board Diagnostic Page 52 of 56 01-51 Read measuring value block (VAG 1551 function 04) Note: To change to another display group within function 04, proceed as follows: Display group VAG 1551 VAG 1552 Higher Press key 3 Press Lower Press key 1 Press Test conditions...
Page 774 On Board Diagnostic Page 53 of 56 01-52 Display group overview Display group 000 (decimal displayed value) Engine running at idle speed, engine control module in "Basic Setting" function 04 Display fields Specification Corresponds 1 2 3 4 5 6 7 93-76 2.25-15 Ignition angle...
Page 775 On Board Diagnostic Page 54 of 56 01-53 Display fields Display group 001 Display xxxx RPM xxx C Indicated Engine Engine coolant Oxygen sensor Ignition timing speed temperature factor Specification 800-880 0.7-1.3 80-110 C 2.25-15 Display group 002 Display xxxx RPM xx.xx ms xx.xx V xxx.x...
Page 776 On Board Diagnostic Page 55 of 56 01-54 Display zones Display group 004 Display xxxx RPM xxx % xxx Km/h xxxxx Indicated Engine Engine load signal Road speed Operating mode1) speed signal Specification 800-880 0-5 % 0 Km/h Relevance page 01-55 Display group 005 Display xxxx RPM...
Page 777 On Board Diagnostic Page 56 of 56 01-55 Relevance of figures in 5-digit number block Relevance when displayed digit = 1 x x x x x Adjustment condition (display group Operating mode (display group 005) 1 Not relevant Overrun Signal from automatic transmission Idle Not relevant Part load...
Page 778 Motronic fuel injection and ignition system Page 1 of 7 24-1 Motronic fuel injection ignition system Component overview 1 - Evaporative Emission (EVAP) canister purge regulator valve -N80- Activated charcoal filter system Repair Manual, 2.0 Liter General, Engine, Repair Group 20 2 - EGR vacuum regulator...
Page 779 Motronic fuel injection and ignition system Page 2 of 7 Mass Air Flow (MAF) sensor - G70- 4 - Throttle Position (TP) sensor - G69- 5 - Motronic Engine Control Module (ECM) - J220- 6 - Harness connector 4-pin Heated Oxygen Sensor (HO2S)
Page 780 Motronic fuel injection and ignition system Page 3 of 7 24-2 7 - Intake Air Temperature (IAT) sensor -G72- 8 - Idle Air Control (IAC) valve -N71- 9 - EGR temperature sensor - G98- Exhaust Gas Recirculation (EGR) system Repair Manual, 2.0 Liter General, Engine, Repair Group 26...
Page 781 Motronic fuel injection and ignition system Page 4 of 7 (VSS) - G22- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 782 Motronic fuel injection and ignition system Page 5 of 7 24-3 Engine Coolant Temperature (ECT) sensor - G62- Color: black With sensor - G2- for gauge 14 - Central connector 15 - 3-pin harness connector knock sensor Color: blue 16 - 3-pin harness connector For RPM...
Page 783 Motronic fuel injection and ignition system Page 6 of 7 24-4 18 - Secondary Injection (AIR) pump motor - V101- Exhaust Gas Recirculation (EGR) system Repair Manual, 2.0 Liter General, Engine, Repair Group 26 19 - Distributor with Camshaft Position (CMP) sensor - G40-...
Page 784 Motronic fuel injection and ignition system Page 7 of 7 23 - Fuel pressure regulator Temperature regulator For intake preheating Evaporative Emissions (EVAP) canister Activated charcoal filter Below air cleaner Repair Manual, 2.0 Liter General, Engine, Repair Group 20 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 785 Motronic fuel injection system, servicing Page 1 of 94 24-5 Motronic fuel injection system, servicing Servicing ignition system Repair Group 28 Note: Fuel hoses in engine compartment must only be secured with spring type clips. The use of clamp or screw type clips is not permissible. The Engine Control Module (ECM) for the fuel injection and ignition system is equipped with Diagnostic Trouble Code (DTC) memory.
Page 786 Motronic fuel injection system, servicing Page 2 of 94 it will lead to damage or sensor malfunctions. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 787 Motronic fuel injection system, servicing Page 3 of 94 24-6 During some checks the ECM will recognize test conditions as a problem and store a malfunction. Therefore, after completing all checks and repairs, the DTC memory must be checked and, if necessary, erased. page 01- Safety precautions page 24-19...
Page 788 Motronic fuel injection system, servicing Page 4 of 94 24-7 Components, removing and installing 1 - Air cleaner Disassembling assembling page 24-16 2 - Harness connector 4-pin For Mass Air Flow (MAF) sensor 3 - Vacuum pipe To EGR vacuum regulator solenoid valve...
Page 789 Motronic fuel injection system, servicing Page 5 of 94 Repair Manual, 2.0 Liter General, Engine, Repair Group 20 6 - Intake air duct 7 - Crankcase breather pressure regulating valve http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 790 Motronic fuel injection system, servicing Page 6 of 94 24-8 8 - Intake manifold, upper First attach tighten to lower intake manifold, then to both rear supports - 23 - Disassembling assembling page 24-16 9 - 30 Nm (22 ft lb) system Repair Manual, 2.0 Liter General,...
Page 791 Motronic fuel injection system, servicing Page 7 of 94 24-9 13 - Harness connector Only disconnect or connect with ignition switched 14 - Mounting plate Motronic J220 15 - 10 Nm (7 ft 16 - Motronic Engine Control Module (ECM) J220* Location: plenum...
Page 792 Motronic fuel injection system, servicing Page 8 of 94 via fuel pump relay, idle air control, ignition and On Board Diagnostic (OBD) Check coding page 01- 17 - To vacuum brake booster http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 793 Motronic fuel injection system, servicing Page 9 of 94 24-10 18 - Retaining clip Check that it is seated securely 19 - O-ring Replace damaged Engine Coolant Temperature (ECT) sensor - G62-* Color: black With sensor G2 for gauge Motronic Checking page 24-54...
Page 794 Motronic fuel injection system, servicing Page 10 of 94 1 and 3 for ECT sensor 22 - 20 Nm (15 ft lb) 23 - Support Between upper intake manifold cylinder head Tighten only after tightening upper intake manifold to lower intake manifold 24 - Gasket...
Page 795 Motronic fuel injection system, servicing Page 11 of 94 24-11 25 - Intake manifold, lower Disassembling assembling page 24-15 26 - Fuel supply hose White arrow Secure with spring- type clips From fuel pump module in fuel tank 27 - Return hose Blue arrow...
Page 796 Motronic fuel injection system, servicing Page 12 of 94 31 - Deflector 32 - Hose To warm collection plate on exhaust manifold Repair Manual, 2.0 Liter General, Engine, Repair Group 26 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 797 Motronic fuel injection system, servicing Page 13 of 94 24-12 33 - Heated Oxygen Sensor (HO2S) - G39-* Tightening torque: 50 Nm (37 ft Location: Three Catalytic Converter (TWC) Only lubricate threads with "G5" Lubricant must not get into slots on probe body Check...
Page 798 Motronic fuel injection system, servicing Page 14 of 94 page 24- Checking oxygen sensor heating page 24-36 34 - Harness connector 4-pin HO2S probe heating circuit Mounted to rear engine mount on right, in direction of travel 35 - Retaining ring http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 799 Motronic fuel injection system, servicing Page 15 of 94 24-13 Intake manifold, upper, disassembling assembling 1 - M6: 10 Nm (7 ft lb)M8: 20 Nm (15 ft lb) 2 - Retainer wiring to valve 3 - Support bracket accelerator pedal cable Adjusting Repair...
Page 800 Motronic fuel injection system, servicing Page 16 of 94 valve 6 - Retaining ring 7 - Intake Air Temperature (IAT) sensor -G72-* Tightening torque: 10 Nm (7 ft Checking page 24-59 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 801 Motronic fuel injection system, servicing Page 17 of 94 24-14 8 - Intake manifold, upper 9 - Gasket Always replace 10 - Throttle valve housing If throttle valve basic setting stop screw has been altered, replace throttle valve housing 11 - 3 Nm (27 in lb) 12 - Throttle Position...
Page 802 Motronic fuel injection system, servicing Page 18 of 94 page 24-46 Automatic transmission only: after removing installing TP sensor, TCM J217 and TP sensor G69 must be matched to one another page 24- 13 - O-ring Replace damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 803 Motronic fuel injection system, servicing Page 19 of 94 24-15 Intake manifold, lower, disassembling assembling 1 - Retaining clip Check that it is securely seated 2 - Strainer 3 - Fuel pressure regulator Checking page 24-82 4 - O-ring Replace damaged 5 - Fuel injectors -...
Page 804 Motronic fuel injection system, servicing Page 20 of 94 24-16 Air cleaner, disassembling assembling 1 - Rubber mount 2 - Air cleaner element 3 - Air cleaner housing, upper 4 - O-ring Replace damaged 5 - Mass Air Flow (MAF) sensor - G70-* 6 - 10 Nm (7 ft...
Page 805 Motronic fuel injection system, servicing Page 21 of 94 8 - Gasket Replace damaged 9 - Mounting plate http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 806 Motronic fuel injection system, servicing Page 22 of 94 24-17 10 - To intake air duct 11 - Vacuum line 12 - Vacuum unit 13 - Air cleaner housing, lower 14 - Bushing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 807 Motronic fuel injection system, servicing Page 23 of 94 24-18 Fig. 1 Temperature sensor resistance The diagram is valid for engine coolant temperature sensor G62 and intake air temperature sensor G72. A - resistance values for the temperature range 0 -50 C (32 - 122 F) B - resistance values for the temperature range 50 -100 C (122 -...
Page 808 Motronic fuel injection system, servicing Page 24 of 94 24-19 Safety precautions WARNING! Be alert when working on or near the engine. High ignition secondary voltage can cause serious personal injury and damage vehicle components. DO NOT touch or disconnect ignition system wires when the engine is running or being cranked at starting RPM.
Page 809 Motronic fuel injection system, servicing Page 25 of 94 After the work is completed, erase Diagnostic Trouble Code (DTC) memory. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 810 Motronic fuel injection system, servicing Page 26 of 94 24-20 CAUTION! BEFORE disconnecting the battery: Stop the engine. Be sure the ignition is switched OFF (also applies when connecting the battery). Failure to do so may damage the Engine Control Module (ECM).
Page 811 Motronic fuel injection system, servicing Page 27 of 94 24-21 Rules for cleanliness CAUTION! Whenever carrying out work on the fuel supply and fuel injection systems, carefully observe the following five rules of cleanliness. 1 - Thoroughly clean fuel system line and hose connections and the surrounding area before disconnecting.
Page 812 Motronic fuel injection system, servicing Page 28 of 94 24-22 Technical data Engine code Idle check 1) Idle speed 2) 800-880 2) Oxygen sensor 1.00 0.25 2)3) factor Motronic Engine Control Module (ECM)4) Part number Parts catalog microfiche Governed engine 5800-6000 speed Observe test conditions...
Page 813 Motronic fuel injection system, servicing Page 29 of 94 24-23 Idle check Idle speed, ignition timing and oxygen sensor factor (CO content) are not adjustable. The idle speed is held to specification by altering the ignition timing, Digital Idle Stabilization (DIS) function. The position of the distributor housing has no influence on ignition timing.
Page 814 Motronic fuel injection system, servicing Page 30 of 94 24-24 Test sequence - Start engine and run at idle speed. - Operate VAG 1551 scan tool taking into account the information on the display - Press button -1- to select "Rapid data transfer" operating mode.
Page 815 Motronic fuel injection system, servicing Page 31 of 94 24-25 CAUTION! Do not continue with the check until engine coolant temperature exceeds 80 C (display field 2). - Briefly increase engine speed (RPM) by pressing on accelerator pedal, then allow engine to run at idle speed for 2 minutes.
Page 816 Motronic fuel injection system, servicing Page 32 of 94 24-26 If RPM specifications are not attained: - Switch ignition off. - Check accelerator pedal mechanism for ease of operation. - Disconnect harness connector from Motronic ECM, then reconnect. - Carry out test drive, check DTC memory, and check idle speed again.
Page 817 Motronic fuel injection system, servicing Page 33 of 94 24-27 Idle air control, checking Functional check - Functional check Output Diagnostic Test Mode (DTM), page 01-39 Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) with VAG 1551/3 adapter cable Test sequence - Start engine and run at idle speed.
Page 818 Motronic fuel injection system, servicing Page 34 of 94 24-28 - Press -0-, -0- and -1- to input display group number 001. - Press -Q- button to confirm input. Indicated on display (1, 2, 3 and 4 Display Read measuring value block 1 fields) 1 2 3 4 Note:...
Page 819 Motronic fuel injection system, servicing Page 35 of 94 24-29 - Disconnect harness connector -1- from engine coolant temperature sensor -2-. Duty cycle must increase, then drop again to original value. Note: Test can only be repeated after the DTC memory has been erased.
Page 820 Motronic fuel injection system, servicing Page 36 of 94 24-30 Heated Oxygen Sensor (HO2S) and oxygen sensor control, checking Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) or vehicle system tester VAG 1552 with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent)
Page 821 Motronic fuel injection system, servicing Page 37 of 94 24-31 Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08. - Press -Q- button to confirm input. Indicated on display Read measuring value block HELP...
Page 822 Motronic fuel injection system, servicing Page 38 of 94 24-32 If the displayed value remains constant: - Press button. - Press buttons -0- and -6- to select "End Output" function 06. - Press -Q- button to confirm input. - Switch ignition off. - Continue check according to following table.
Page 823 Motronic fuel injection system, servicing Page 39 of 94 24-33 Checking basic voltage - Separate 4-pin HO2S harness connector. - Start engine and run at idle speed. - Connect multimeter to measure voltage at connector terminals 3 and 4 of connector. Specification: Approx.
Page 824 Motronic fuel injection system, servicing Page 40 of 94 24-34 - Separate 4-pin HO2S harness connector. - Check wiring for open circuits between test box and 4-pin connector, according to wiring diagram. Terminal 3+socket 42 Terminal 4+socket 20 Wire resistance: Max. 1.5 - Check wires at 4-pin connector for shorts to one another.
Page 825 Motronic fuel injection system, servicing Page 41 of 94 24-35 - Check shielding for short to HO2S wiring according to wiring diagram. Terminal 3 and test box socket 56 Terminal 4 and test box socket 56 Specification: If the specifications are not attained: - Check wiring according to wiring diagram.
Page 826 Motronic fuel injection system, servicing Page 42 of 94 24-36 Oxygen sensor heating, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram Test conditions HO2S relay OK Engine coolant temperature at least 80 C (176 F) Test sequence...
Page 827 Motronic fuel injection system, servicing Page 43 of 94 24-37 If the specification is attained: - Start engine and run at idle speed. - Connect multimeter to measure voltage at HO2S connector terminals 1 and 2. Specification: approx. battery positive voltage (B+) - Switch ignition off.
Page 828 Motronic fuel injection system, servicing Page 44 of 94 24-38 Engine operating mode, checking Note: This check establishes whether the Motronic ECM J220 recognizes the engine operating condition. Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) or vehicle system tester VAG 1552 with VAG 1551/3 adapter cable Test conditions...
Page 829 Motronic fuel injection system, servicing Page 45 of 94 24-39 Indicated on display (1, 2, 3 and 4 = Read measuring value block 4 Display fields) 1 2 3 4 Note: If something different is indicated on the display: Scan tool operating instructions Display for operating modes: Overrun mode: - Increase engine speed to above...
Page 830 Motronic fuel injection system, servicing Page 46 of 94 24-40 Wide open throttle: - Floor accelerator pedal and release. 2nd position from left must briefly display 1; Display: 01000 Acceleration enrichment: - Floor accelerator (rev-up to above 3000 RPM). 1st position from left must display 1; Display: 10000 - Press button.
Page 831 Motronic fuel injection system, servicing Page 47 of 94 24-41 Mass Air Flow (MAF) sensor, checking Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) or vehicle system tester VAG 1552 with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram...
Page 832 Motronic fuel injection system, servicing Page 48 of 94 24-42 - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08. - Press -Q- button to confirm input. Indicated on display Read measuring value block HELP Input display group number XXX - Press -0-, -0- and -1- to input display group number 001.
Page 833 Motronic fuel injection system, servicing Page 49 of 94 24-43 If the specification is not attained or the value remains constant when revving-up: - Continue check according to following table. Display Cause Continuation of check Check wiring page Open circuit in wire 4 24-44 Short circuit...
Page 834 Motronic fuel injection system, servicing Page 50 of 94 24-44 Checking voltage supply - Separate 4-pin connector to MAF sensor. - Connect multimeter to measure voltage at connector terminals 1 and - Switch ignition on. Specification: Min. 9 volts - Switch ignition off. - Reconnect MAF sensor harness connector.
Page 835 Motronic fuel injection system, servicing Page 51 of 94 24-45 - Check wiring for open circuits between test box and 4-pin connector, according to wiring diagram. Terminal 2 and test box socket Terminal 4 and test box socket Wire resistance: Max. 1.5 - Check wires at 4-pin connector for shorts to one another.
Page 836 Motronic fuel injection system, servicing Page 52 of 94 24-46 Throttle Position (TP) sensor, checking Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) or vehicle system tester VAG 1552 with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram...
Page 837 Motronic fuel injection system, servicing Page 53 of 94 24-47 Indicated on display (1, 2, 3 and 4 = Read measuring value block 3 Display fields) 1 2 3 4 Note: If something different is indicated on the display: Scan tool operating instructions - Check throttle valve angle at closed throttle position in display field 3.
Page 838 Motronic fuel injection system, servicing Page 54 of 94 24-48 If the value does not increase uniformly: - Replace throttle position sensor. If the value remains constant: - Continue check according to following table. Display Cause Continuation of check Open circuit Check wiring in wire 2 page 24-50...
Page 839 Motronic fuel injection system, servicing Page 55 of 94 24-49 Checking voltage supply - Separate 3-pin connector from throttle position sensor. - Connect multimeter to measure voltage at connector terminals 1 and - Switch ignition on. Specification: min. 4.5 V - Switch ignition off.
Page 840 Motronic fuel injection system, servicing Page 56 of 94 24-50 - Check wiring for open circuits between test box and 3-pin connector, according to wiring diagram. Terminal 1 and test box socket Terminal 3 and test box socket Wire resistance: Max. 1.5 - Check wires at 3-pin connector for shorts to one another.
Page 841 Motronic fuel injection system, servicing Page 57 of 94 24-51 If the display shows constant 106 - Switch ignition on. - Check wire for short circuit to positive. - Connect multimeter to measure voltage at test box sockets 1 and 40 Specification: 0 volts - Switch ignition off Continuation if voltage is present:...
Page 842 Motronic fuel injection system, servicing Page 58 of 94 24-52 Continuation if no voltage is present: - Separate 3-pin connector to throttle position sensor. - Check wiring for open circuits between test box and 3-pin connector, according to wiring diagram. Terminal 2 and test box socket 40 Wire resistance: Max.
Page 843 Motronic fuel injection system, servicing Page 59 of 94 24-53 Transmission Control Module (TCM) and Throttle Position (TP) sensor, matching Note: On automatic transmission vehicles, the TCM J217 and the TP sensor G69 must be matched to one another after the following work has been completed: Replacement of TCM Removal and installation of throttle position...
Page 844 Motronic fuel injection system, servicing Page 60 of 94 24-54 Engine Coolant Temperature (ECT) sensor, checking Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) or vehicle system tester VAG 1552 with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram...
Page 845 Motronic fuel injection system, servicing Page 61 of 94 24-55 Read measuring value block HELP - Press -0-, -0- and -1- to input display Input display group number XXX group number 001. - Press -Q- button to confirm input. Indicated on display (1, 2, 3 and 4 = Read measuring value block 1 Display fields) 1 2 3 4...
Page 846 Motronic fuel injection system, servicing Page 62 of 94 24-56 Functional check of sensor Display Cause Continuation of check Open circuit page 24-57 77.7 C or short to positive Short to ground Temperature value increases uniformly1) If the temperature that is displayed deviates greatly from the ambient temperature of the sensor, check sensor wiring for transfer resistance.
Page 847 Motronic fuel injection system, servicing Page 63 of 94 24-57 Continuation of check when display = 77.7 C - Connect VAG 1598/18 test box to ECM wiring harness. - Disconnect 4-pin harness connector - 1- from engine coolant temperature sensor G62 -2-. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 848 Motronic fuel injection system, servicing Page 64 of 94 24-58 - Check wiring for open circuits between test box and 4-pin connector, according to wiring diagram. Terminal 1 and test box socket Terminal 3 and test box socket Wire resistance: Max. 1.5 - Check wiring between ECM connector and 4-pin connector terminal 3 for short circuit to terminal...
Page 849 Motronic fuel injection system, servicing Page 65 of 94 24-59 Intake Air Temperature (IAT) sensor, checking Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) or vehicle system tester VAG 1552 with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram...
Page 850 Motronic fuel injection system, servicing Page 66 of 94 24-60 - Press -0-, -0- and -3- to input display group number 003. - Press -Q- button to confirm input. Indicated on display (1, 2, 3 and 4 = Display fields) Reading measured value block 3 1 2 3 4 Note:...
Page 851 Motronic fuel injection system, servicing Page 67 of 94 24-61 Continuation of check when display = 19.6 C - Switch ignition off. - Connect VAG 1598/18 test box to ECM wiring harness. - Disconnect 2-pin harness connector - 1- from intake air temperature sensor G72 -2-.
Page 852 Motronic fuel injection system, servicing Page 68 of 94 24-62 - Check wiring for open circuits between test box and 2-pin connector, according to wiring diagram. Terminal 1 and test box socket Terminal 2 and test box socket Wire resistance: Max. 1.5 - Check wiring between ECM connector and 2-pin connector terminal 2 for short circuit to terminal...
Page 853 Motronic fuel injection system, servicing Page 69 of 94 24-63 Continuation of check when display = ambient temperature - Remove intake air temperature sensor G72 (harness connector remains connected). - Note intake air temperature value in display field 4. - Spray sensor with chilling spray (commercially available) while observing temperature display.
Page 854 Motronic fuel injection system, servicing Page 70 of 94 24-64 Engine Speed (RPM) sensor, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram Test sequence - Disconnect 3-pin harness connector from sensor -1-.
Page 855 Motronic fuel injection system, servicing Page 71 of 94 24-65 - Connect VAG 1598/18 test box to ECM wiring harness. - Check wiring for open circuits between test box and 3-pin connector -1-, according to wiring diagram. Terminal 1 and test box socket Terminal 2 and test box socket Terminal 3 and test box socket Wire resistance: Max.
Page 856 Motronic fuel injection system, servicing Page 72 of 94 24-66 - Additionally check wires for short to one another. Terminal 1 and test box socket 68 Terminal 1 and test box socket 56 Terminal 2 and test box socket 56 Specification: (no continuity) If no wiring malfunction is detected:...
Page 857 Motronic fuel injection system, servicing Page 73 of 94 24-67 Vehicle speed signal, checking Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) or vehicle system tester VAG 1552 with VAG 1551/3 adapter cable Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram Test conditions...
Page 858 Motronic fuel injection system, servicing Page 74 of 94 24-68 - Press -Q- button to confirm input. Indicated on display Read measuring value block HELP Input display group number XXX - Press -0-, -0- and -4- to input display group number 004. - Press -Q- button to confirm input.
Page 859 Motronic fuel injection system, servicing Page 75 of 94 24-69 If no speed is indicated: - Disconnect 3-pin harness connector from sensor -1-. - Switch ignition on. - Check voltage between connector terminals 1 and 3. Specification: Min. 9 volts - Switch ignition off.
Page 860 Motronic fuel injection system, servicing Page 76 of 94 24-70 If voltage was min. 9 volts: - Connect VAG 1598/18 test box to ECM wiring harness. - Check wire for open circuit between single connector (behind central electrics) and test box socket 65, according to wiring diagram.
Page 861 Motronic fuel injection system, servicing Page 77 of 94 24-71 Engine Control Module (ECM) voltage supply, checking Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) or vehicle system tester VAG 1552 with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram...
Page 862 Motronic fuel injection system, servicing Page 78 of 94 24-72 - Press -Q- button to confirm input. Indicated on display Read measuring value block HELP Input display group number XXX - Press -0-, -0- and -2- to input display group number 002. - Press -Q- button to confirm input.
Page 863 Motronic fuel injection system, servicing Page 79 of 94 24-73 If the displayed value fluctuates or the battery voltage is not attained: - Switch ignition off. - Connect VAG 1598/18 test box to ECM wiring harness. - Switch ignition on. - Bridge sockets 1 and 9 with adapter cables from VW 1594 connector test kit.
Page 864 Motronic fuel injection system, servicing Page 80 of 94 24-74 Checking voltage supply terminal 15 - Check voltage with multimeter between test box sockets 1 and 38 using adapter cables from VW 1594 test kit. Specification: Min. 9 volts If the specification is not attained: - Check wiring according to wiring diagram.
Page 865 Motronic fuel injection system, servicing Page 81 of 94 24-75 Air conditioning compressor signal, checking Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) or vehicle system tester VAG 1552 with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram...
Page 866 Motronic fuel injection system, servicing Page 82 of 94 24-76 - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08. - Press -Q- button to confirm input. Indicated on display Read measuring value block HELP Input display group number XXX - Press -0-, -0- and -5- to input display group number 005.
Page 867 Motronic fuel injection system, servicing Page 83 of 94 24-77 Fuel injectors, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VAG 1527B voltage tester VW 1594 connector test kit Wiring diagram Check conditions Engine speed sender OK.
Page 868 Motronic fuel injection system, servicing Page 84 of 94 24-78 If LED does not flicker: - Switch ignition off. - Connect VAG 1598/18 test box to ECM wiring harness. - Check wiring for open circuits between test box and connector, according to wiring diagram.
Page 869 Motronic fuel injection system, servicing Page 85 of 94 24-79 - Check wiring for open circuit between fuel injector connector terminal 1 and relay panel, according to wiring diagram. Wire resistance: Max. 1.5 - Additionally check wires for short to one another.
Page 870 Motronic fuel injection system, servicing Page 86 of 94 24-80 Fuel injector spray pattern and leakage, checking WARNING! The fuel system is pressurized! Before loosening hose connections or opening the test connection, wrap a cloth around the connection. Then release pressure by carefully loosening and disconnecting the hose or fitting.
Page 871 Motronic fuel injection system, servicing Page 87 of 94 24-81 - Disconnect harness connector from engine coolant temperature sensor G62. - Set VAG 1630 digital potentiometer scale A to 15k and connect to connector terminals 1 and 3 using adapter cables from VW 1594 test kit.
Page 872 Motronic fuel injection system, servicing Page 88 of 94 24-82 Fuel pressure regulator and residual pressure, checking The fuel pressure regulator controls the fuel pressure dependent upon intake manifold pressure. Special tools, testers and auxiliary items VAG 1318 pressure gauge VAG 1318/10 adapter VAG 1318/11 adapter VAG 1318/16 adapter...
Page 873 Motronic fuel injection system, servicing Page 89 of 94 24-83 Test sequence - Disconnect fuel supply hose -1- from fuel rail -2- and connect to VAG 1318 pressure gauge using VAG 1318/10 adapter. - Connect VAG 1318 pressure gauge to fuel rail -2- using VAG 1318/11 and VAG 1318/16 adapters.
Page 874 Motronic fuel injection system, servicing Page 90 of 94 24-84 - After pressure has built up switch ignition off and at the same time close gauge valve; handle 90 to flow (arrow). - Watch pressure drop on gauge. If the pressure drops again: - Check fuel pump check valve.
Page 875 Motronic fuel injection system, servicing Page 91 of 94 24-85 Intake air system, checking for leaks (outside air) Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) or vehicle system tester VAG 1552 with VAG 1551/3 adapter cable Engine leak detector spray G 001 800 A1 WARNING! The safety precautions listed on the leak...
Page 876 Motronic fuel injection system, servicing Page 92 of 94 24-86 - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08. - Press -Q- button to confirm input. Indicated on display Read measuring value block HELP Input display group number XXX - Press -0-, -0- and -1- to input display group number 001.
Page 877 Motronic fuel injection system, servicing Page 93 of 94 24-87 Intake air preheating, checking Special tools, testers and auxiliary items VAG 1390 hand vacuum pump Checking regulating flap Regulating flap vacuum unit must not be leaking - Remove upper air cleaner housing and remove air cleaner element.
Page 878 Motronic fuel injection system, servicing Page 94 of 94 24-88 Checking temperature regulator - Connect vacuum line to temperature regulator (brass connecting pipe or with notch). - Start engine and run at idle speed. - Check position of regulating flap after max. 20 seconds.
Page 879 Motronic fuel injection and ignition system Page 1 of 1 28-1 Motronic fuel injection and ignition system Note: Only the components that specifically relate to the ignition system are dealt with in this Repair Group. For the other components of the fuel injection and ignition system Repair Group The fuel injection and ignition system Engine...
Page 880 Motronic ignition system, servicing Page 1 of 25 28-2 Motronic ignition system, servicing Note: Motronic Engine Control Module (ECM) J220* with connector page 24-9 , item 16 . 1 - High- voltage ignition cable Ignition secondary circuit Check continuity 2 - Suppressor Resistance: 0.6-1.4 k 3 - Ignition...
Page 881 Motronic ignition system, servicing Page 2 of 25 page 28-20 6 - 10 Nm (7 ft 7 - Ignition coil -N152- Checking page 28-19 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 882 Motronic ignition system, servicing Page 3 of 25 28-3 8 - Harness connector 3-pin 9 - Ground (GND) strap 10 - Knock Sensor (KS) 1 - G61-* 11 - 20 Nm (15 ft lb) Tightening torque influences knock sensor function 12 - Spark plug connector 3277...
Page 883 Motronic ignition system, servicing Page 4 of 25 Spark plug type electrode page 28- 14 - 25 Nm (18 ft lb) 15 - Clamp http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 884 Motronic ignition system, servicing Page 5 of 25 28-4 16 - O-ring Replace damaged 17 - Distributor with Camshaft Position (CMP) sensor - G40-* Installing page 28-8 Checking sensor page 28- 18 - Dust cap 19 - Rotor arm Marking: Resistance: 0.6-1.4 k 20 - Distributor...
Page 885 Motronic ignition system, servicing Page 6 of 25 Check carbon brush for wear and freedom movement 21 - Shielding http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 886 Motronic ignition system, servicing Page 7 of 25 28-5 Safety precautions WARNING! Be alert when working on or near the engine. High ignition secondary voltage can cause serious personal injury and damage vehicle components. DO NOT touch or disconnect ignition system wires when the engine is running or being cranked at starting RPM.
Page 887 Motronic ignition system, servicing Page 8 of 25 After the work is completed, erase Diagnostic Trouble Code (DTC) memory. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 888 Motronic ignition system, servicing Page 9 of 25 28-6 CAUTION! BEFORE disconnecting the battery: Stop the engine. Be sure the ignition is switched OFF (also applies when connecting the battery). Failure to do so may damage the Engine Control Module (ECM). Be sure of the proper radio code (for vehicles equipped with coded anti-theft radio).
Page 889 Motronic ignition system, servicing Page 10 of 25 28-7 Technical data, spark plugs Engine code Ignition timing1) Checking page 24-23 Firing order 1-3-4-2 Spark plugs1) VW/Audi 101 000 044 Manufacturer's FR 8 DS designation Electrode gap 2) 0.8 mm (0.031 in.) Tightening torque 30 Nm (22 ft lb)
Page 890 Motronic ignition system, servicing Page 11 of 25 28-8 Distributor, removing and installing Special tools, testers and auxiliary items Pin wrench Matra V159 Torque wrench VAG 1331 (5-50 Note: The Motronic Engine Control Module (ECM) requires the Cyl. 1 TDC signal from the camshaft position sensor in the distributor in order to allocate the fuel injection and knock sensor systems...
Page 891 Motronic ignition system, servicing Page 12 of 25 28-9 Engine removed Set vibration damper (V-belt pulley) to mark for Cyl.1 TDC. Mark on camshaft sprocket must align with arrow on cylinder head cover. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 892 Motronic ignition system, servicing Page 13 of 25 28-10 Mark on distributor housing must align with mark on rotor arm or camshaft position sensor cover. Removing Crankshaft and camshaft in Cyl.1 TDC position - Remove distributor. Installing - Align oil pump shaft drive lug parallel to crankshaft.
Page 893 Motronic ignition system, servicing Page 14 of 25 28-11 - Install distributor. Pins on distributor must point toward mounting bolt threaded hole (arrow). Note: When installing, turn the rotor arm slightly the the right of the distributor marking (clockwise). When inserting the distributor and meshing the drive gears, the rotor arm will turn back toward the marking.
Page 894 Motronic ignition system, servicing Page 15 of 25 28-12 - Turn intermediate shaft sprocket with toothed drive belt (in direction of arrows) until rotor arm aligns with markings for Cyl.1 on distributor housing. (Toothed belt slides over crankshaft sprocket.) Mark on distributor housing must align with mark on rotor arm or camshaft position sensor cover.
Page 895 Motronic ignition system, servicing Page 16 of 25 28-13 - Turn tensioner with pin wrench (e.g. Matra V159) in direction of arrow to adjust toothed drive belt tension. It must be just possible to turn the toothed belt through 90 with the thumb and forefinger in the center between camshaft and intermediate shaft sprockets.
Page 896 Motronic ignition system, servicing Page 17 of 25 28-14 Ignition timing control, checking Special tools, testers and auxiliary items VAG 1767 ignition tester, or VAG 1367 ignition tester with VAG 1367/8 HT pick-up clamp Check conditions Engine oil temperature at least 80 C (176 F) Test sequence - Connect VAG 1767 ignition tester, or...
Page 897 Motronic ignition system, servicing Page 18 of 25 28-15 Camshaft Position (CMP) sensor, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram Test sequence - Disconnect harness connector from sensor (distributor).
Page 898 Motronic ignition system, servicing Page 19 of 25 28-16 - Check wiring for open circuits between test box and 3-pin connector, according to wiring diagram. Terminal 1 and test box socket Terminal 2 and test box socket Terminal 3 and test box socket Wire resistance: Max.
Page 899 Motronic ignition system, servicing Page 20 of 25 28-17 Knock sensor, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram Test sequence - Disconnect brown 3-pin harness connector -2- from knock sensor 1 G61 socket -1-.
Page 900 Motronic ignition system, servicing Page 21 of 25 28-18 - Check wiring between test box and 3-pin connector for open circuit according to wiring diagram. Terminal 1 and test box socket Terminal 2 and test box socket Terminal 3 and test box socket Wire resistance: Max.
Page 901 Motronic ignition system, servicing Page 22 of 25 28-19 Ignition coil, checking Special tools, testers and auxiliary items Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Test sequence - Disconnect harness connector and high-voltage cable from ignition coil N152. - Check primary resistance with between terminals 1 and 15 with multimeter.
Page 902 Motronic ignition system, servicing Page 23 of 25 28-20 Ignition coil power output stage, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VAG 1527B voltage tester VW 1594 connector test kit Wiring diagram Checking voltage supply - Disconnect 3-pin harness connector from ignition coil.
Page 903 Motronic ignition system, servicing Page 24 of 25 28-21 - Connect VAG 1598/18 test box to ECM wiring harness. - Check wire for open circuit between test box socket 38 and 3-pin connector terminal 3, according to wiring diagram. Wire resistance: Max. 1.5 Checking activation - Disconnect harness connector for fuel injectors 1 and 4, and remove...
Page 904 Motronic ignition system, servicing Page 25 of 25 28-22 - Connect VAG 1598/18 test box to ECM wiring harness. - Check wire for open circuit between test box socket 8 and 3-pin connector terminal 2, according to wiring diagram. Wire resistance: Max. 1.5 - Additionally check wires for short to one another.
Page 907 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1996-1997 01 - On Board Diagnostic (OBD) On Board Diagnostic (OBD) Malfunction Indicator Lamp (MIL), significance On Board Diagnostic (OBD) technical data VAG 1551 Scan Tool (ST), connecting and selecting "Engine Electronics" address word 01 Control module, coding (function 07) Diagnostic Trouble Code (DTC) memory, checking (function 02)
Page 908 Oxygen Sensor (O2S) heating, checking (after three way catalytic converter) Oxygen Sensor (O2S) aging, checking (before three way catalytic converter) Engine operation, checking Mass Air Flow (MAF) sensor, checking Throttle valve control module -J338-, checking Basic setting, initiating Engine Coolant Temperature (ECT) sensor -G62-, checking Intake Air Temperature (IAT) sensor -G72-, checking Engine speed (RPM) sensor -G28-, checking Speedometer Vehicle Speed Sensor (VSS) -G22- signal, checking...
Page 909 On Board Diagnostic (OBD) Page 1 of 6 01-1 On Board Diagnostic (OBD) Function The Engine Control Module (ECM) -J220- for the fuel injection and ignition system is equipped with a Diagnostic Trouble Code (DTC) memory. If malfunctions occur in the sensors and components being monitored, they will be stored in the DTC memory together with an indication of the type of malfunction.
Page 910 On Board Diagnostic (OBD) Page 2 of 6 01-2 Malfunction Indicator Lamp (MIL), significance If malfunctions are recognized and verified by the engine control module, they will be indicated by switching on the malfunction indicator lamp. Location of malfunction indicator lamp (MIL) Note: The MIL can be switched on in the...
Page 911 On Board Diagnostic (OBD) Page 3 of 6 01-3 Functional check: - Switch ignition on: MIL must light-up. If the MIL does not light-up with ignition switched on: - Check wiring to MIL as follows. Cause: Remedy: MIL is not activated or does not - Switch ignition off light-up due to open circuit - Connect test box VAG 1598/18...
Page 912 On Board Diagnostic (OBD) Page 4 of 6 01-4 If the MIL lights-up with ignition switched on, continue check as follows: - Start engine and run at idle speed. MIL must go out after a few seconds. If the MIL does not go out: - Check DTC memory Page 01-12 If no malfunction is stored:...
Page 913 On Board Diagnostic (OBD) Page 5 of 6 01-5 On Board Diagnostic (OBD) technical data Equipped with Diagnostic Trouble Code (DTC) memory Rapid data transfer Engine control module identification Page 01-7 ; VAG 1551 Scan Tool (ST), connecting and selecting Engine Electronics address word 01 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 914 On Board Diagnostic (OBD) Page 6 of 6 01-6 Engine Control Module (ECM) functions Note: The ECM is equipped with various functions. Some functions can be carried out with ignition switched on or with engine running. The following table details the requirements for performing the individual functions.
Page 915 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word 01 Page 1 of 80 01-7 VAG 1551 Scan Tool (ST), connecting and selecting "Engine Electronics" address word 01 Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Note: The VAG 1552 scan tool can be used instead of...
Page 916 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word 01 Page 2 of 80 01-8 Note: If the display does not show as indicated in the work sequence: VAG 1551 scan tool operating instructions If due to an input malfunction "Error in communication link"...
Page 917 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word 01 Page 3 of 80 01-9 HS V02 = Manual transmission with Motronic system version 02 Coding 00006 = Coding variants WSC = Workshop code Coding variants: Coding Application 00006 Passat with manual transmission...
Page 918 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word 01 Page 4 of 80 01-10 Control module, coding (function 07) If the appropriate code for the vehicle is not displayed or if the control module has been replaced, the control module must be coded as follows.
Page 919 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word 01 Page 5 of 80 01-11 Indicated on display Code Control Module HELP Input code number XXXXX (0-32000) - Input appropriate code number for this vehicle and press -Q- button to confirm input.
Page 920 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word 01 Page 6 of 80 01-12 Diagnostic Trouble Code (DTC) memory, checking (function 02) Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Work sequence - Connect VAG 1551/1552 scan tool and select "Engine Electronics"...
Page 921 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word 01 Page 7 of 80 01-13 If one or more malfunctions are stored, the malfunctions stored will be displayed and printed out one after the other. If no malfunction is stored: - Press button.
Page 922 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word 01 Page 8 of 80 01-14 Diagnostic Trouble Code (DTC) table Note: The DTC overview is listed according to SAE or VAG codes. After repairing malfunctions, DTC memory must be erased ( Page 01-31 ) and the repair verified via the appropriate display group...
Page 923 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word 01 Page 9 of 80 01-15 Malfunction text Malfunction elimination 00577 Knock Sensor - Check knock sensor and knock control Page Control Cyl. 1 28-25 Control limit exceeded 00578 Knock Sensor - Correct abnormal engine running noises Control Cyl.
Page 924 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 10 of 80 01-16 Malfunction text Malfunction elimination 00668 Battery Positive Voltage - Check generator: (B+) Term. 30 Electrical Wiring Diagrams, Troubleshooting & Component Locations signal too high Battery Positive Voltage - Check battery (B+) Term.
Page 925 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 11 of 80 01-17 Diagnostic code Malfunction text Malfunction elimination (DTC) P0102 16486 Mass or Volume Air Flow Circuit - Check Mass Air Flow (MAF) Low Input sensor Page 24-63 P0103...
Page 926 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 12 of 80 01-18 Diagnostic code Malfunction text Malfunction elimination (DTC) P0120 16504 Throttle Position Sensor A - Check throttle valve control module Circuit Malfunction Page 24-69 - Check MAF sensor Page 24-63 P0121...
Page 927 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 13 of 80 01-19 Diagnostic code Malfunction text Malfunction elimination (DTC) P0137 16521 02 Sensor Circuit Low - Check HO2S 2 and O2S control Voltage (Bank 1, Sensor 2) (after three way catalytic converter) Page 24-43 P0138...
Page 928 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 14 of 80 01-20 Diagnostic code Malfunction Malfunction elimination (DTC) text P0171 16555 System too Lean - Check intake air system for leaks Page 24- (Bank 1) - Check HO2S and O2S control (before three way catalytic converter) Page 24-26...
Page 929 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 15 of 80 01-21 Diagnostic code Malfunction Malfunction elimination (DTC) text P0172 16556 System too Rich - Check HO2S and O2S control (before three (Bank 1) way catalytic converter) Page 24-26 - Check fuel pressure regulator Page 24-121...
Page 930 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 16 of 80 01-22 Diagnostic code Malfunction text Malfunction elimination (DTC) P0301 16685 Cylinder 1 Misfire Detected - Check fuel injectors Page 01-72 (output DTM) and Page 24-116 P0302 16686 Cylinder 2 Misfire Detected...
Page 931 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 17 of 80 01-23 Diagnostic code Malfunction text Malfunction elimination (DTC) P0422 16806 Main Catalyst Efficiency Below - Check HO2S and O2S control Threshold (Bank 1) (before three way catalytic converter) Page 24-26 - Check O2S aging (before three...
Page 932 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 18 of 80 01-24 Diagnostic code Malfunction text Malfunction elimination (DTC) P1127 17535 Long Term Fuel Trim - Check MAF sensor Page 24-63 mul. (B1) System too Rich - Check HO2S and O2S control (before three way catalytic converter)
Page 933 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 19 of 80 01-25 Diagnostic code Malfunction text Malfunction elimination (DTC) P1128 17536 Long Term Fuel Trim - Check HO2S and O2S control (before mul. (B1) System too three way catalytic converter) Page 24- Lean...
Page 934 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 20 of 80 01-26 Diagnostic code Malfunction text Malfunction elimination (DTC) P1213 17621 Cyl.1-Fuel Injector - Check fuel injectors Page 01-72 , output Circ. Short to B+ Diagnostic Test Mode (DTM) and Page 24-116...
Page 935 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 21 of 80 01-27 Diagnostic code Malfunction text Malfunction elimination (DTC) P1300 17708 Misfire detected - Fill vehicle fuel tank Reason: Fuel level too low P1340 17748 Camshaft/Crankshaft - Check engine speed (RPM) sensor Pos.Sens.Signals Out of...
Page 936 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 22 of 80 01-28 Diagnostic code Malfunction text Malfunction elimination (DTC) P1450 17858 Sec.Air Inj.Sys.Circ. - Check Secondary Air Injection (AIR) pump Short to B+ relay -J299- Page 01-72 , output Diagnostic Test Mode (DTM) and:...
Page 937 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 23 of 80 01-29 Diagnostic code Malfunction text Malfunction elimination (DTC) P1543 17951 Throttle Actuation - Check throttle valve control module Potentiometer Signal Page 24-69 too Low P1544 17952 Throttle Actuation...
Page 938 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 24 of 80 01-30 Diagnostic code Malfunction text Malfunction elimination (DTC) P1611 18019 MIL Call-up Circ./Transm.Control - Check wiring between Module Short to Ground Transmission Control Module (TCM) and ECM: Electrical Wiring Diagrams, Troubleshooting &...
Page 939 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 25 of 80 01-31 Diagnostic Trouble Code (DTC) memory, erasing (function 05) Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Test conditions Malfunctions eliminated Engine coolant temperature must reach at...
Page 940 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 26 of 80 01-32 Indicated on display Rapid data transfer DTC memory is erased - Press button. Indicated on display Rapid data transfer HELP Select function XX - Allow engine to idle for at least 1 minute and check DTC memory again.
Page 941 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 27 of 80 01-33 Readiness code, reading (function 15) Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Work sequence - Connect VAG 1551/1552 scan tool and, with ignition switched on, select "Engine Electronics"...
Page 942 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 28 of 80 01-34 - Create readiness code Page 01-35 - Read readiness code Page 01-33 . If DTC memory has been erased, repair must be verified via appropriate display group Page 01-35 , Readiness code, creating.
Page 943 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 29 of 80 01-35 Readiness code, creating Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Note: During test sequence the ignition must not be switched off.
Page 944 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 30 of 80 01-36 Work step: 1 - Connect VAG 1551/1552 scan tool and select "Engine Electronics" address word 01 Page 01-7 When doing this, the ignition must be switched Relevance of 8-digit number block in display field 4 1 2 3 4 5 6 7 8 Diagnostic status...
Page 945 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 31 of 80 01-37 Note: There must not be any malfunctions stored in DTC memory or detected during this diagnostic test. If the CYCLE bit has a 1, the diagnosis is completed and the test sequence can be implemented.
Page 946 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 32 of 80 01-38 Work step: 3 Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -5- to select "Erase DTC Memory" function 05 and press -Q- button to confirm input.
Page 947 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 33 of 80 01-39 Display fields Display group 103 Display xx.xx ms xxxx xxxx xxx.x C xxx.x C Indicated Engine Engine coolant Three way catalytic Diagnosis load temperature converter conditions...
Page 948 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 34 of 80 01-40 Work step: 6 Diagnosis: Secondary Air Injection (AIR) system Test conditions Vehicle stationary, engine at idle - Press buttons -0- and -4- to select "Basic Setting"...
Page 949 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 35 of 80 01-41 Display fields Display group160 Display xxxx xxxx xx.x % xx.x % xxx.x C Indicated Engine coolant Secondary air Secondary air Diagnosis conditions temperature injection valve injection pump open...
Page 950 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 36 of 80 01-42 Work step: 7 Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Q- button to confirm input.
Page 951 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 37 of 80 01-43 Display fields Display group 103 Display xx.xx ms xxxx xxxx xxx.x C xxx.x C Indicated Engine Engine coolant Three way catalytic Diagnosis load temperature converter conditions...
Page 952 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 38 of 80 01-44 Work step: 8 Diagnosis: Oxygen Sensor (O2S) aging (regulating frequency extended) Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -4- to select "Basic Setting"...
Page 953 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 39 of 80 01-45 Display fields Display group 131 Display x.xxx V xxxx rpm xxxx ms xxxx xxxx Indicated Voltage of HO2S Engine HO2S aging Diagnosis after three way speed conditions catalytic...
Page 954 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 40 of 80 01-46 Work step: 9 Diagnosis: Oxygen Sensor (O2S) adaptation in partial load range Indicated on display Basic Setting HELP Input display group number XXX - Press buttons -1-, -2- and -5- to input display group 125 and press -Q- button to confirm input.
Page 955 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 41 of 80 01-47 Display fields Display group 125 Display x.x % xxxx rpm x.x % xxxx xxxx Indicated Engine speed O2S adaptation Diagnosis adaptation at at part load conditions idle Specification...
Page 956 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 42 of 80 01-48 Work step: 10 Diagnosis: Oxygen Sensor (O2S) adaptation in idle range Test conditions Engine coolant temperature min. 60 C (140 F) ( display group 001, display field 2) Intake air temperature max.
Page 957 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 43 of 80 01-49 Display fields Display group 125 Display x.x % xxxx rpm x.x % xxxx xxxx Indicated Oxygen sensor Engine Oxygen sensor Diagnosis adaptation at part speed adaptation at idle conditions...
Page 958 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 44 of 80 01-50 Work step: 11 Diagnosis: Oxygen Sensor (O2S) aging (regulating frequency extended) Test conditions Vehicle stationary Indicated on display Basic Setting HELP Input display group number XXX - Press buttons -1-, -3- and -0- to input display group 130 and press -Q- button to confirm input.
Page 959 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 45 of 80 01-51 Display fields Display group 130 Display xxxx rpm xx s xxxx xxxx Indicated Engine Seconds Period counter Diagnosis speed conditions Specification 2200...2800 0...2.8 s 1111 x100 Period duration of O2S Heated Oxygen...
Page 960 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 46 of 80 01-52 Work step: 12 Diagnosis: Three Way Catalytic Converter (TWC) Indicated on display Basic Setting HELP Input display group number XXX - Press buttons -1-, -3- and -6- to input display group 136 and press -Q- button to confirm input.
Page 961 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 47 of 80 01-53 Display fields Display group 136 Display xxxx rpm x.xx xxxx xxxx xxx.x C Indicated Engine Three way catalytic Amplitude Diagnosis speed converter temp. ratio conditions Specification...
Page 962 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 48 of 80 01-54 Work step: 14 Diagnosis: Fuel tank venting system (EVAP canister purge regulator valve) Test conditions Vehicle stationary Electrical consumers switched off (radiator coolant fan must not run during the check) Air conditioner switched off Note:...
Page 963 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 49 of 80 01-55 Display fields Display group 150 Display xx % x.x % x.xx g/s xxxx xxxx Indicated Opening Oxygen Sensor Idling control Diagnosis degrees (O2S) control conditions Specification 0...100 %...
Page 964 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 50 of 80 01-56 Work step: 14 - Read readiness code Page 01-33 - If the readiness code is not OK, perform optional work steps 15 through 21 Page 01-56 Work step: 15 Diagnosis: Vehicle Speed Sensor (VSS)
Page 965 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 51 of 80 01-57 - Check specifications during test drive (second technician necessary). See airbag warning Page 01-35 Display fields Display group 180 Display xxxx rpm km/h xxxx xxxx xxx.x C Indicated...
Page 966 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 52 of 80 01-58 Work step: 16 Diagnosis: Knock Sensor (KS) Test conditions Vehicle stationary Indicated on display Basic Setting HELP Input display group number XXX - Press buttons -1-, -4- and -5- to input display group 145 and press -Q- button to confirm input.
Page 967 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 53 of 80 01-59 Display fields Display group 145 Display xxxx rpm xxxx xxxx Indicated Engine Knock Sensor (KS) Wiring open Diagnosis speed circuit counter conditions Specification At least max.
Page 968 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 54 of 80 01-60 Work step: 17 Diagnosis: Heated Oxygen Sensor (HO2S) (before three way catalytic converter) Indicated on display Basic Setting HELP Input display group number XXX - Press buttons -1-, -1- and -5- to input display group 115 and press -Q- button to confirm input.
Page 969 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 55 of 80 01-61 Relevance of 8 digit number block in display field 4 1 2 3 4 5 6 7 8 Specifications of diagnosis conditions HO2S before Three Way Catalytic Converter (TWC) is switched on HO2S is operationally warm HO2S before TWC is operationally ready...
Page 970 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 56 of 80 01-62 Work step: 18 Diagnosis: Heated Oxygen Sensor (HO2S) after three way catalytic converter Indicated on display (1-4 = display fields) System in Basic Setting 1 2 3 4 - Increase engine speed to 2200-2800 RPM and check specifications after 15...
Page 971 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 57 of 80 01-63 Relevance of 8 digit number block in display field 4 1 2 3 4 5 6 7 8 Specifications of diagnosis conditions Oxygen sensor heating after Three Way Catalytic Converter (TWC) is switched on HO2S is operationally warm HO2S after TWC operationally ready...
Page 972 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 58 of 80 01-64 Work step: 19 Diagnosis: Oxygen Sensor (O2S) heating (before and after three way catalytic converter) Indicated on display Basic Setting HELP Input display group number XXX - Press buttons -1-, -2- and -0- to input display group 120 and press -Q- button to confirm input.
Page 973 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 59 of 80 01-65 Display fields Display group 120 Display xxx s xxxx xxxx xxx.x C xx.x Indicated TWC temp. Seconds Resistance Diagnosis conditions Specification At least 360 Approx.
Page 974 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 60 of 80 01-66 Indicated on display (1-4 = display System in Basic Setting fields) 1 2 3 4 - Increase engine speed to 2200-2800 RPM and check specifications. Display fields Display group 121 Display...
Page 975 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 61 of 80 01-67 Relevance of 8 digit number block in display field 4 1 2 3 4 5 6 7 8 Specifications of diagnosis conditions O2S heating after TWC switched on O2S after TWC vaporization point exceeded HO2S after TWC operationally ready O2S heating after TWC operationally ready...
Page 976 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 62 of 80 01-68 Work step: 20 Diagnosis: Throttle valve control module Note: There are no specifications for this diagnosis. The values in the display fields are typical for this diagnosis.
Page 977 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 63 of 80 01-69 Indicated on display (1-4 = System in Basic Setting display fields) 1 2 3 4 - Run engine at idle speed. Display fields Display group 141 Display xx %...
Page 978 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 64 of 80 01-70 Indicated on display (1-4 = System in Basic Setting display fields) 1 2 3 4 - Run engine at idle speed. Display fields Display group 142 Display xx.x %...
Page 979 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 65 of 80 01-71 Work step: 21 - Read readiness code Page 01-33 - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input.
Page 980 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 66 of 80 01-72 Output Diagnostic Test Mode (DTM) (function 03) The output Diagnostic Test Mode (DTM) actuates the following components in the stated sequence: 1 - Cylinder 1 fuel injector -N30- 2 - Cylinder 2 fuel injector -N31- 3 - Cylinder 3 fuel injector -N32- 4 - Cylinder 4 fuel injector -N33-...
Page 981 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 67 of 80 01-73 Test conditions Throttle Position (TP) sensor -G69- OK Fuse 18 OK Test sequence - Connect VAG 1551/1552 scan tool and with ignition switched on, select "Engine Electronics" address word 01 Page 01-7 Indicated on display...
Page 982 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 68 of 80 01-74 To activate fuel injectors for cylinders 2-4, in each case: - Open throttle fully again and close. Skipping individual tests: - Press button. If one or more fuel injectors do not click: - Continue output Diagnostic Test Mode (DTM) to the end.
Page 983 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 69 of 80 01-75 - During output DTM blow into auxiliary hose (in direction of throttle housing). Valve must open and close If the purge regulator valve does not open and close: - Disconnect 2-pin connector from valve and connect VAG 1527B voltage tester with test...
Page 984 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 70 of 80 01-76 - Check wiring between 2-pin connector terminal 2 and central electrical panel for open circuit according to wiring diagram. Resistance: max. 1.5 ohms ( ) - Check wiring between ECM connector and 2-pin connector terminal 1 for short circuit to terminal 2 and to vehicle Ground (GND), according to...
Page 985 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 71 of 80 01-77 If secondary air injection solenoid valve does not switch: - Disconnect 2-pin connector from Secondary Air Injection (AIR) solenoid valve -N112- -2-. - Connect VAG 1527B voltage tester to 2-pin connector using test leads from VW 1594.
Page 986 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 72 of 80 01-78 - Check wiring between ECM connector and 2-pin connector terminal 1 for short circuit to terminal 2 and to vehicle Ground (GND), according to wiring diagram.
Page 987 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 73 of 80 01-79 - Connect VAG 1527B voltage tester to 2-pin connector using test leads from VW 1594. LED must light up. IF LED lights up (voltage supply OK): - Replace Secondary Air Injection (AIR) pump motor -V101-.
Page 988 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 74 of 80 01-80 - Press key. Indicated on display Output Diagnostic Test Mode (DTM) EVAP canister purge solenoid valve-N115 Disregard display. - Press key. Indicated on display Rapid data transfer HELP Select function XX...
Page 989 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 75 of 80 01-81 Measuring value block, reading (function 08) Note: To change to another display group proceed as follows: Display VAG 1551 scan VAG 1552 scan group tool tool...
Page 990 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 76 of 80 01-82 Display group overview Display group 000 (decimal displayed value) Engine running at idle speed, control module in "Read Measuring Value Block" Display fields Specification Corresponds 1 2 3 4 5 6 7 8 9 10 Partial load adaptation...
Page 991 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 77 of 80 01-83 Note: Press button to end "Read Measuring Value Block". After terminating "Read Measuring Value Block", press buttons -0- and -6- to input "End Output"...
Page 992 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 78 of 80 01-84 Display Possible malfunction cause Malfunction elimination field: 3 Less than - Selector lever in P or N position Driving range selected - Check throttle valve control module Throttle valve control module Page 24-69 faulty...
Page 993 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 79 of 80 01-85 Display Possible malfunction Malfunction elimination field: 6 + 7 cause Less than Unmetered air after - Check intake air system for leaks Page 24- throttle valve More than - Switch off consumer...
Page 994 VAG 1551 Scan Tool (ST), connecting and selecting 'Engine Electronics' address word... Page 80 of 80 01-86 Display field: 9 Possible malfunction Malfunction cause elimination Less than 241 or more than 14 Page 24-30 , evaluating display group 025 Display field: 10 Possible malfunction Malfunction cause...
Page 995 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 1 of 17 01-87 VAG 1551 Scan Tool (ST), connecting and selecting "CARB/OBD II" address word Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Test conditions Fuses 15, 18 and 22 OK...
Page 996 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 2 of 17 01-88 Display will appear as shown Rapid data transfer 33 - OBD II - Press Q button to confirm input. Display will appear as shown OBD II Scan Tool Select mode 1..
Page 997 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 3 of 17 01-89 Current data, mode 1 In mode 1 the current diagnostic data can be interrogated. Additionally the readiness code can be displayed (PID1 display field 4).
Page 998 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 4 of 17 01-90 Diagnostic data Relevance of figures in 8 digit number block Display will appear as shown Mode 41 PID 1 Module 10 00000000 xxxxxxxx xxxxxxxx xxxxxxxx Display positions 2...8 indicate number of DTCs stored Display positions Specification...
Page 999 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 5 of 17 01-91 Relevance of figures in 8 digit number block Display will appear as shown Mode 41 PID 1 Module 10 xxxxxxxx xxxxxxxx 01101101 xxxxxxxx If specification is 0, the diagnostic capability is not recognized by ECM.
Page 1000 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 6 of 17 01-92 Display will appear as shown Mode 41 PID 1 Module 10 xxxxxxxx xxxxxxxx xxxxxxxx 00000000 If the specification is not obtained in display field 4 and a 1 is displayed, then the appropriate diagnostic sequence has not yet been performed.
Page 1001 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 7 of 17 01-93 - Press button to display any additional diagnostic data. Mode 41 PID 3 Module 10 PID3: Fuel injection system status Fuel System xxxxx1xx xxxxxxxx When the 3rd position from the right is 1, the injection status is recognized as available.
Page 1002 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 8 of 17 01-94 - Press button. Mode 41 PID 6 Module 10 PID6: Short Term Fuel Trim, Bank 1 Short Term Fuel Trim Bank 1 The oxygen sensor control integrator in % is displayed here.
Page 1003 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 9 of 17 01-95 - Press button. Mode 41 PID 13 Module 1A PID13: Vehicle speed (mph) Speed x km/h Current vehicle speed display - Press button.
Page 1004 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 10 of 17 01-96 - Press button. Mode 41 PID 16 Module 10 PID16: Mass air flow g/sec Air Flow Rate 4.30 g/sec Measured at idle approx.: 4.3 g/sec. If the value is below 2.5 g/sec.
Page 1005 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 11 of 17 01-97 - Press button. Mode 41 PID 20 Module 10 PID20: Heated oxygen sensor 1: 0.445 V x% Bank 1 Sensor 1 0.445 V The displayed value in volts must fluctuate between 0 and 1.0 volts.
Page 1006 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 12 of 17 01-98 Freeze frame data, mode 2 Note: If a malfunction that illuminates the MIL is detected by the Engine Control Module (ECM) and is then stored, simultaneously, the operating conditions existing at the time the malfunction was stored will also be stored, and can be interrogated via mode 2.
Page 1007 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 13 of 17 01-99 DTC memory, mode 3 - Press -3- button to select mode 3 DTC memory. Display will appear as shown x Malfunction recognized Module 10* Module 10* or 1A* will be activated MIL off Module 1A*...
Page 1008 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 14 of 17 01-100 Clear DTC memory, mode 4 - Start engine and let idle. Press -4- button to select mode 4 clear DTC memory. Note: DTC codes (if any are stored) must first be read before they can be cleared.
Page 1009 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 15 of 17 01-101 Oxygen sensor signal (B1-S1), mode 5 Note: When a Heated Oxygen Sensor (HO2S) malfunction is stored, use mode 5 to check the HO2S signal output, to see whether the HO2S before three way catalytic converter is within specification, or whether another...
Page 1010 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 16 of 17 01-102 Display will appear as shown: Test ID Mode 45 Test ID 2 Module 10 B1-S1 0.445V Lean/rich threshold voltage: constant value 0.445 volts If constant value is not obtained, the HO2S is faulty - Press...
Page 1011 VAG 1551 Scan Tool (ST), connecting and selecting 'CARB/OBD II' address word 33 Page 17 of 17 01-103 - Press button Display will appear as shown: Test ID Mode 45 Test ID 8 Module 10 B1-S1 0.598V x.xxV 1.078V Maximum test voltage If the actual value is above 1.078 volts, there is a short circuit to positive (B+) in the wire to HO2S...
Page 1012 Multiport fuel injection and ignition system Page 1 of 144 24-1 Multiport fuel injection ignition system Component locations, overview 1 - Evaporative Emission (EVAP) canister purge regulator valve -N80- EVAP system Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA m.y.
Page 1013 Multiport fuel injection and ignition system Page 2 of 144 (ECM) - J220- 5 - Connector Brown, 4-pin Heated Oxygen Sensor (HO2S) 2 -G108-and Oxygen Sensor (O2S) heating (after three way catalytic converter); installation position: Three Catalytic Converter (TWC) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1014 Multiport fuel injection and ignition system Page 3 of 144 24-2 6 - Connector Black, 4- Heated Oxygen Sensor (HO2S) - G39- and Oxygen Sensor (O2S) heating (before three way catalytic converter) Location: front exhaust pipe 7 - Intake Air Temperature (IAT) sensor -G72-...
Page 1015 Multiport fuel injection and ignition system Page 4 of 144 Black, with Engine Coolant Temperature (ECT) sensor -G2- 11 - Center connector 12 - 3-pin connector knock sensor Blue 13 - 3-pin connector engine speed sensor 14 - Engine speed (RPM) sensor - G28-...
Page 1016 Multiport fuel injection and ignition system Page 5 of 144 24-3 15 - Secondary Injection (AIR) pump motor - V101- Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA m.y. 1995 - 1997, Repair Group 26 16 - Distributor With Camshaft Position...
Page 1017 Multiport fuel injection and ignition system Page 6 of 144 item 10 19 - Ground (GND) connection 20 - Fuel pressure regulator Temperature regulator Thermal Vacuum Valve (TVV) For intake preheating 22 - EVAP canister Below air cleaner EVAP system Repair Manual, 2.0 Liter 4-Cyl.
Page 1018 Multiport fuel injection and ignition system Page 7 of 144 24-4 General information Fuel injection system, servicing Ignition system, servicing Repair Group 28 Note: Fuel hoses in engine compartment must be secured with spring type clips. The use of clamp or screw type clips is not permissible. The control module for the fuel injection and ignition system is equipped with a Diagnostic Trouble Code (DTC) memory.
Page 1019 Multiport fuel injection and ignition system Page 8 of 144 damage/malfunctions. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1020 Multiport fuel injection and ignition system Page 9 of 144 24-5 During some checks it can happen that the ECM will recognize and store a malfunction. Therefore after completing all checks and repairs the DTC memory must be checked and if necessary erased Page 01-12 , checking...
Page 1021 Multiport fuel injection and ignition system Page 10 of 144 24-6 Fuel injection system, components 1 - Air Cleaner (ACL) Disassembling assembling Page 24-16 2 - Connector 4-pin Mass Air Flow (MAF) sensor - G70- 3 - Evaporative Emission (EVAP) canister purge regulator...
Page 1022 Multiport fuel injection and ignition system Page 11 of 144 (PCV) valve 6 - Connector 8-pin throttle valve control module - J338- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1023 Multiport fuel injection and ignition system Page 12 of 144 24-7 7 - Intake manifold, upper First tighten to lower intake manifold and then to both rear supports - 21 - Page 24- Disassembling assembling Page 24-16 8 - Throttle valve control module -...
Page 1024 Multiport fuel injection and ignition system Page 13 of 144 plate Engine Control Module (ECM) - J220- 11 - 10 Nm (7 ft http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1025 Multiport fuel injection and ignition system Page 14 of 144 24-8 12 - Engine Control Module (ECM) - J220-* Location: plenum chamber, right side For fuel injection system, Oxygen Sensor (O2S) control, Evaporative Emission (EVAP) canister purge regulator valve, speed governing via fuel pump relay,...
Page 1026 Multiport fuel injection and ignition system Page 15 of 144 Page 24- 13 - To brake booster 14 - To A/C 15 - Retaining clip Check seated securely 16 - O-ring Replace damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1027 Multiport fuel injection and ignition system Page 16 of 144 24-9 Engine Coolant Temperature (ECT) sensor - G62-* Black, Engine Coolant Temperature (ECT) sensor -G2- Input to fuel injection system Checking Page 24-89 necessary before removing, release pressure from cooling system 18 - Connector 4-pin...
Page 1028 Multiport fuel injection and ignition system Page 17 of 144 manifold upper section cylinder head 22 - Gasket Always replace 23 - Intake manifold, lower Disassembling assembling Page 24-15 24 - Engine speed (RPM) sensor - G28-* 25 - Spacer ring http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 1029 Multiport fuel injection and ignition system Page 18 of 144 24-10 26 - Heated Oxygen Sensor (HO2S) 2 - G108- * 50 Nm (37 ft lb) Installation position: Three Catalytic Converter (TWC) Grease only threads with Part No. G 052 112 A3 hot bolt paste (anti-seize...
Page 1030 Multiport fuel injection and ignition system Page 19 of 144 Checking heating Page 24-50 CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. 27 - Connector Brown, 4-pin For HO2S 2 -G108- and O2S heating (after...
Page 1031 Multiport fuel injection and ignition system Page 20 of 144 24-11 28 - Heated Oxygen Sensor (HO2S) -G39- 50 Nm (37 ft lb) Installation position: before Three Way Catalytic Converter (TWC) Grease only threads with Part No. G 052 112 A3 hot bolt paste (anti- seizecompound).
Page 1032 Multiport fuel injection and ignition system Page 21 of 144 Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. 29 - Connector Black, 4-pin For HO2S and oxygen sensor heating (before three way catalytic converter) Secured to...
Page 1033 Multiport fuel injection and ignition system Page 22 of 144 24-12 30 - Deflector 31 - To crankcase 32 - Hose To warm deflector plate on exhaust manifold Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA m.y. 1995 - 1997, Repair Group 26 33 - Retaining...
Page 1034 Multiport fuel injection and ignition system Page 23 of 144 type clips To fuel tank http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1035 Multiport fuel injection and ignition system Page 24 of 144 24-13 Intake manifold, upper, removing and installing 1 - M6: 10 Nm (7 ft lb) M8: 20 Nm (15 ft 2 - Throttle valve control module - J338-* Checking Page 24-69 replaced, "Basic...
Page 1036 Multiport fuel injection and ignition system Page 25 of 144 (TP) sensor - G69- Closed Throttle Position (CTP) switch - F60- 3 - Retainer 4 - Support bracket accelerator pedal cable Adjusting accelerator pedal cable: Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s):...
Page 1037 Multiport fuel injection and ignition system Page 26 of 144 24-14 5 - Intake Air Temperature (IAT) sensor -G72- * 10 Nm (7 ft lb) Checking Page 24-95 6 - Intake manifold, upper 7 - Gasket Always replace http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1038 Multiport fuel injection and ignition system Page 27 of 144 24-15 Intake manifold, lower, removing and installing 1 - Retaining clip Check securely seated 2 - Strainer 3 - Fuel pressure regulator Checking Page 24-121 4 - O-ring Replace damaged 5 - Fuel Injectors*/** Cylinder...
Page 1039 Multiport fuel injection and ignition system Page 28 of 144 7 - 10 Nm (7 ft 8 - Fuel rail http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1040 Multiport fuel injection and ignition system Page 29 of 144 24-16 Air Cleaner (ACL), removing and installing 1 - Rubber grommet 2 - Air cleaner element 3 - Air cleaner housing, upper 4 - O-ring Replace damaged 5 - Mass Air Flow (MAF) sensor -...
Page 1041 Multiport fuel injection and ignition system Page 30 of 144 regulator flap Intake air preheating, checking Page 24-127 8 - Gasket Replace damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1042 Multiport fuel injection and ignition system Page 31 of 144 24-17 9 - Mounting plate 10 - To intake hose 11 - Vacuum hose 12 - Vacuum unit 13 - Air cleaner housing, lower 14 - Spacer http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1043 Multiport fuel injection and ignition system Page 32 of 144 24-18 Fig. 1 Resistance graph The diagram applies to Engine Coolant Temperature (ECT) sensor -G62- and Intake Air Temperature (IAT) sensor - G72-. Scale A shows resistance values for temperature range 0 -50 C (32 - 122 F) and scale B shows the values for temperature range 50 -100 C (122 -212 F).
Page 1044 Multiport fuel injection and ignition system Page 33 of 144 24-19 Safety precautions WARNING! Fuel system is under pressure! Before opening the system place a rag around the connection. Then release pressure by slowly loosening the connection. Be alert when working on or near the engine. High ignition secondary voltage can cause serious personal injury and damage vehicle components.
Page 1045 Multiport fuel injection and ignition system Page 34 of 144 Disconnect harness connectors from all fuel injectors. After the work is completed, erase DTC memory. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1046 Multiport fuel injection and ignition system Page 35 of 144 24-20 CAUTION! BEFORE disconnecting the battery: Stop the engine. Be sure the ignition is switched OFF (also applies when connecting the battery). Failure to do so may damage the Engine Control Module (ECM).
Page 1047 Multiport fuel injection and ignition system Page 36 of 144 24-21 Rules for cleanliness CAUTION! Whenever carrying out work on the fuel supply and fuel injection systems, carefully observe the following five rules of cleanliness. 1 - Thoroughly clean fuel system line and hose connections and the surrounding area before disconnecting.
Page 1048 Multiport fuel injection and ignition system Page 37 of 144 24-22 Technical data Engine code Idle check Idle speed 800 to 880 Oxygen sensor control 2)3) -5.0 to 5.0 factor Ignition timing 2.0 to 15.0 2)3) Engine control module (ECM) Part number Parts catalog...
Page 1049 Multiport fuel injection and ignition system Page 38 of 144 24-23 Idle speed, checking Idle speed, ignition timing and CO content not adjustable. The idle speed is regulated by the throttle valve control module. The position of the distributor has no influence on ignition timing.
Page 1050 Multiport fuel injection and ignition system Page 39 of 144 24-24 Test sequence Engine running at idle - Connect VAG 1551/1552 scan tool and select "Engine Electronics" address word 01 Page 01-7 Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -4- to select "Basic Setting"...
Page 1051 Multiport fuel injection and ignition system Page 40 of 144 24-25 Display fields Display group 001: Idle test Display xxxx RPM xx.x% xxx.x C xx.x Indicated Engine speed Coolant Oxygen Sensor Ignition angle temperature (O2S) control Working 800 - 6000 RPM -25.0 to 25.0% 0.0 - 40.0 range...
Page 1052 Multiport fuel injection and ignition system Page 41 of 144 24-26 Heated Oxygen Sensor (HO2S) and Oxygen Sensor (O2S) control, checking (before three way catalytic converter) Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594...
Page 1053 Multiport fuel injection and ignition system Page 42 of 144 24-27 Indicated on display Read Measuring Value Block HELP Input display group number XXX - Press buttons -0-, -2- and -5- to input display group 025 and press -Q- button to confirm input.
Page 1054 Multiport fuel injection and ignition system Page 43 of 144 24-28 Continuation If the specification in display field 1 is not attained, or the value does not fluctuate at least - Perform a test drive to remove possible residue on HO2S and repeat check. If the the specification in display field 1 is not attained even after a road test, or the value does not fluctuate at least 2%:...
Page 1055 Multiport fuel injection and ignition system Page 44 of 144 24-29 Display fields Display group 115: Heated Oxygen Sensor (HO2S) before Three Way Catalytic Converter (TWC) Display xxxxxxxx x.xxx V xxx.x C xxx.x C Indicated Coolant Exhaust gas O2S control HO2S voltage (before temperature temperature...
Page 1056 Multiport fuel injection and ignition system Page 45 of 144 24-30 Evaluating display group 025 Display group: Possible malfunction cause Malfunction elimination Display field: 2 and 3 Adaptation Crankcase dilution: when the - Oil change or a fast drive on values in range: partial load adaptation value country roads...
Page 1057 Multiport fuel injection and ignition system Page 46 of 144 If O2S control adaptation is not active: - Check Mass Air Flow (MAF) sensor Page 24-63 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1058 Multiport fuel injection and ignition system Page 47 of 144 24-31 Evaluating display group 115 Display Possible malfunction cause Malfunction group: 115 elimination Display field: Approx. Open circuit in wire 4 between Heated Oxygen - Check basic voltage 0.435 V Sensor (HO2S) and Engine Control Module Page 24-33 (ECM)
Page 1059 Multiport fuel injection and ignition system Page 48 of 144 24-32 Relevance of values in 8-digit number block Relevance when display = 1 x x x x x x x x O2S control status (display O2S control status (display group 025) group 115) 1 HO2S ready (before TWC) Malfunction in DTC memory...
Page 1060 Multiport fuel injection and ignition system Page 49 of 144 24-33 Checking basic voltage - Separate 4-pin connector (black) -1- to HO2S -G39- (before three way catalytic converter). - Connect multimeter with test leads from VW 1594 to measure voltage between terminals 3 and 4 (ECM side of harness connector).
Page 1061 Multiport fuel injection and ignition system Page 50 of 144 24-34 Checking Heated Oxygen Sensor (HO2S) wiring - Connect VAG 1598/18 test box to ECM wiring harness. - Separate 4-pin connector -1- (black) to HO2S -G39- (before three way catalytic converter). http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 1062 Multiport fuel injection and ignition system Page 51 of 144 24-35 - Check wiring between test box and 4-pin connector for open circuit according to wiring diagram (ECM side of harness connector). Terminal 3 and test box socket Terminal 4 and test box socket Resistance: maximum 1.5 ohms ( ) - Additionally, check wiring at 4-pin connector for short circuit to one...
Page 1063 Multiport fuel injection and ignition system Page 52 of 144 24-36 Oxygen Sensor (O2S) heating, checking (before three way catalytic converter) Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram...
Page 1064 Multiport fuel injection and ignition system Page 53 of 144 24-37 Indicated on display Read Measuring Value Block HELP Input display group number XXX - Press buttons -1-, -2- and -0- to input display group 120 and press -Q- button to confirm input.
Page 1065 Multiport fuel injection and ignition system Page 54 of 144 24-38 - Press button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Relevance of values in 8-digit number block Relevance if display = 1 x x x x x x x x Oxygen sensor control status (display group 120) 1 Malfunction in DTC memory...
Page 1066 Multiport fuel injection and ignition system Page 55 of 144 24-39 Continuation - Separate 4-pin connector -1- (black) to HO2S -G39- (before three way catalytic converter). - Connect multimeter with test leads from VW 1594 to measure resistance at terminals 1 and 2 on connector to HO2S.
Page 1067 Multiport fuel injection and ignition system Page 56 of 144 24-40 If the specification is attained: - Check relevance table Page 24-38 for value of O2S control status, display group 120, display field 4, 1st position from left. - Set multimeter to voltage measurement range. - Connect multimeter using test leads from VW 1594 to measure voltage between terminals 1 and 2 (ECM side of harness connector).
Page 1068 Multiport fuel injection and ignition system Page 57 of 144 24-41 If voltage was present: - Check relevance table Page 24-38 for value of O2S control status, display group 120, display field 4, 1st position from left. - Connect multimeter using test leads from VW 1594 between terminal 2 (ECM side of harness connector) and battery positive (B+).
Page 1069 Multiport fuel injection and ignition system Page 58 of 144 24-42 - Check wiring between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 2 and test box socket 12 Resistance: maximum 1.5 ohms ( ) If no wiring malfunction is detected: - Replace Engine Control Module (ECM) -J220-.
Page 1070 Multiport fuel injection and ignition system Page 59 of 144 24-43 Heated Oxygen Sensor (HO2S) 2 and Oxygen Sensor (O2S) control, checking (after three way catalytic converter) Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent)
Page 1071 Multiport fuel injection and ignition system Page 60 of 144 24-44 Indicated on display Read Measuring Value Block HELP Input display group number XXX - Press buttons -1-, -1- and -6- to input display group 116 and press -Q- button to confirm input.
Page 1072 Multiport fuel injection and ignition system Page 61 of 144 24-45 Continuation - Perform a test drive to remove possible residue from HO2S and repeat check. If the specification in display field 3 is not attained even after a test drive: - Check O2S heating Page 24-50 - Increase engine speed to above 3000 RPM.
Page 1073 Multiport fuel injection and ignition system Page 62 of 144 24-46 Relevance of values in 8-digit number block Relevance if display = 1 x x x x x x x x O2S control status (display group 116) 1 Malfunction in Diagnostic Trouble Code (DTC) memory Malfunction detected during this diagnosis Diagnosis completed during this drive Diagnosis currently active...
Page 1074 Multiport fuel injection and ignition system Page 63 of 144 24-47 Checking basic voltage - Separate 4-pin connector -2- (brown) to HO2S 2 -G108- (after three way catalytic converter). - Connect multimeter using test leads from VW 1594 to measure voltage between terminals 3 and 4 (ECM side of harness connector).
Page 1075 Multiport fuel injection and ignition system Page 64 of 144 24-48 Checking Heated Oxygen Sensor (HO2S) wiring - Connect VAG 1598/18 test box to ECM wiring harness. - Separate 4-pin connector -2- (brown) to HO2S 2 -G108- (after three way catalytic converter).
Page 1076 Multiport fuel injection and ignition system Page 65 of 144 24-49 - Check wiring between test box and 4-pin connector to ECM for open circuit according to wiring diagram. Terminal 3 and test box socket Terminal 4 and test box socket Resistance: maximum 1.5 ohms ( ) - Additionally, check wiring to 4-pin connector for short circuits to one...
Page 1077 Multiport fuel injection and ignition system Page 66 of 144 24-50 Oxygen Sensor (O2S) heating, checking (after three way catalytic converter) Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram...
Page 1078 Multiport fuel injection and ignition system Page 67 of 144 24-51 Indicated on display Read Measuring Value Block HELP Input display group number XXX - Press buttons -1-, -2- and -1- to input display group 121 and press -Q- button to confirm input.
Page 1079 Multiport fuel injection and ignition system Page 68 of 144 24-52 - Press button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Relevance of values in 8-digit number block Relevance when display = 1 x x x x x x x x O2S control status (display group 121)
Page 1080 Multiport fuel injection and ignition system Page 69 of 144 24-53 Continuation - Separate 4-pin connector -2- (brown) to HO2S 2 -G108- (after three way catalytic converter). - Connect multimeter with test leads from VW 1594 to measure resistance at terminals 1 and 2 on connector to HO2S 2.
Page 1081 Multiport fuel injection and ignition system Page 70 of 144 24-54 If the specification is attained: - Check relevance table Page 24-52 for value of O2S control status, display group 121, display field 4, 1st position from left. - Set multimeter to voltage measurement range. - Connect multimeter with test leads from VW 1594 to measure voltage between terminals 1 and 2 (ECM side of harness connector).
Page 1082 Multiport fuel injection and ignition system Page 71 of 144 24-55 If voltage was present: - Check relevance table Page 24-52 for value of O2S control status, display group 121, display field 4, 1st position from left. - Connect multimeter with test leads from VW 1594 between terminal 2 (ECM side of harness connector) and battery positive (B+).
Page 1083 Multiport fuel injection and ignition system Page 72 of 144 24-56 - Check wiring between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 2 and test box socket 66 Resistance: maximum 1.5 ohms ( ) If no wiring malfunction is detected: - Replace Engine Control Module (ECM) -J220-.
Page 1084 Multiport fuel injection and ignition system Page 73 of 144 24-57 Oxygen Sensor (O2S) aging, checking (before three way catalytic converter) Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Test conditions Coolant temperature at least 80 C (176 F) Functional check Engine running at idle - Connect VAG 1551/1552 scan tool and select...
Page 1085 Multiport fuel injection and ignition system Page 74 of 144 24-58 Note: During the test, engine RPM must be held for at least 1 minute so that exhaust gas temperature is within specification range. Observe O2S control status in display field 4. Display fields Display group 130: Oxygen Sensor (O2S) aging (monitoring signal frequency of HO2S)
Page 1086 Multiport fuel injection and ignition system Page 75 of 144 24-59 Display fields Display group 131: Oxygen Sensor (O2S) aging (O2S control signal frequency extended) Display xxxx xx.xxx V xxx ms xxxxxxxx Indicated Engine HO2S voltage (after Signal O2S control speed three way catalytic frequency...
Page 1087 Multiport fuel injection and ignition system Page 76 of 144 24-60 Relevance of values in 8-digit number block Relevance when display = 1 x x x x x x x x O2S control status (display O2S control status (display group 130) group 131) 1 Malfunction in Diagnostic Malfunction in DTC...
Page 1088 Multiport fuel injection and ignition system Page 77 of 144 24-61 Engine operation, checking Note: Check establishes whether Engine Control Module (ECM) -J220-recognizes the engine operating condition. Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Test conditions Engine oil temperature min.
Page 1089 Multiport fuel injection and ignition system Page 78 of 144 24-62 If the specifications are not attained: Indicated on display (1-4 Display Read Measuring Value Block fields) 1 2 3 4 - Check whether ECM recognizes operating mode (display field 4). Display fields Display group 005: General engine data Display...
Page 1090 Multiport fuel injection and ignition system Page 79 of 144 24-63 Mass Air Flow (MAF) sensor, checking Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram Test conditions...
Page 1091 Multiport fuel injection and ignition system Page 80 of 144 24-64 Indicated on display Read Measuring Value Block HELP Input display group number XXX - Press buttons -0-, -1- and -5- for display group number 015 and press -Q- button to confirm input.
Page 1092 Multiport fuel injection and ignition system Page 81 of 144 24-65 - Press -C- button. - Press buttons -0-, -1- and -6- for display group number 016 and press -Q- button to confirm input. Indicated on display (1-4 Display fields) Read Measuring Value Block 1 2 3 4 - Check load registration specifications 2 (display...
Page 1093 Multiport fuel injection and ignition system Page 82 of 144 24-66 Evaluating display group 016 Display group Possible malfunction cause Malfunction elimination Display field: 3 0.00 ms Wiring open circuit in wire 3 or 4 between - Check voltage supply Mass Air Flow (MAF) sensor and ECM Page 24-66 Smallest value:...
Page 1094 Multiport fuel injection and ignition system Page 83 of 144 24-67 Checking wiring - Switch ignition off. - Connect VAG 1598/18 test box to ECM wiring harness. - Check wiring between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 2 and test box socket Terminal 4 and test box socket Resistance: maximum 1.5 ohms ( )
Page 1095 Multiport fuel injection and ignition system Page 84 of 144 24-68 - Set multimeter to voltage measurement range. - Check 4-pin connector terminals for short circuit to battery positive (B+) according to wiring diagram. Terminal 2 and vehicle Ground (GND) Terminal 4 and vehicle Ground (GND) Specification: 0 volts If no wiring malfunction is detected:...
Page 1096 Multiport fuel injection and ignition system Page 85 of 144 24-69 Throttle valve control module -J338-, checking Note: If the Throttle valve control module -J338- is removed and installed or replaced, "Basic Setting" function 04 must be initiated for matching of system components Page 24-86 Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3...
Page 1097 Multiport fuel injection and ignition system Page 86 of 144 24-70 - Connect multimeter using adapter cables from VW 1594 to measure voltage at terminals 4 and 7 of connector. Specification: 4.0-6.0 volts - Switch ignition off. If the specifications are not attained: - Connect VAG 1598/18 test box to ECM wiring harness.
Page 1098 Multiport fuel injection and ignition system Page 87 of 144 24-71 - Check wiring at 8-pin connector for short circuit to each other. Terminal 7 and test box socket Terminal 7 and test box socket Terminal 4 and test box socket Specification: ohms ( ) - Reconnect connector.
Page 1099 Multiport fuel injection and ignition system Page 88 of 144 24-72 Indicated on display Read Measuring Value Block HELP Input display group number XXX - Press buttons -0-, -0- and -5- for display group 005 and press -Q- button to confirm input. Indicated on display (1-4 Display Read Measuring Value Block...
Page 1100 Multiport fuel injection and ignition system Page 89 of 144 24-73 Continuation - Switch ignition off. - Connect VAG 1598/18 test box to ECM wiring harness. - With throttle valve closed connect multimeter to measure resistance at test box sockets 10 and 33. Specification: maximum 5.0 ohms ( - Slowly open throttle.
Page 1101 Multiport fuel injection and ignition system Page 90 of 144 24-74 - Check wiring at 8-pin connector for short circuit between terminal 7 and test box socket 10. Specification: ohms ( ) - Reconnect connector. If no wiring malfunction is detected: - Replace Throttle valve control module -J338-.
Page 1102 Multiport fuel injection and ignition system Page 91 of 144 24-75 Indicated on display Read Measuring Value Block HELP Input display group number XXX - Press buttons -0-, -3- and -7- for display group 037 and press -Q- button to confirm input. Indicated on display (1-4 Display Read Measuring Value Block...
Page 1103 Multiport fuel injection and ignition system Page 92 of 144 24-76 - Press -C- button. - Press buttons -0-, -3- and -6- for display group number 036 and press -Q- button to confirm input. Indicated on display (1-4 Display fields) Read Measuring Value Block 1 2 3 4 - Check specifications for idle control (display field...
Page 1104 Multiport fuel injection and ignition system Page 93 of 144 24-77 Evaluating display group 037 Display group: Possible malfunction cause Malfunction elimination Display field: 3 Idle control in Load increased (electrical - Switch off electrical consumers range: 4.0 to consumers switched on) 16.0% -4.0 to -16.0% Unmetered air behind throttle...
Page 1105 Multiport fuel injection and ignition system Page 94 of 144 24-78 Evaluating display group 036 Display group: Possible malfunction Malfunction elimination Display field: 2 cause Mass air flow Load increased - Switch off electrical consumers adaptation (electrical consumers value: switched on) 0.50 to 1.70% -0.50 to -1.70% Unmetered air behind...
Page 1106 Multiport fuel injection and ignition system Page 95 of 144 24-79 Continuation - Switch ignition off. - Connect VAG 1598/18 test box to ECM wiring harness. - Switch ignition on. - With throttle closed connect multimeter to measure resistance at test box sockets 27 and 53.
Page 1107 Multiport fuel injection and ignition system Page 96 of 144 24-80 - Check wiring between test box and 8-pin connector for open circuit according to wiring diagram. Terminal 1 and test box socket 27 Terminal 2 and test box socket 53 Terminal 7 and test box socket 33 Terminal 8 and test box socket 62 Resistance: maximum 1.5 ohms ( )
Page 1108 Multiport fuel injection and ignition system Page 97 of 144 24-81 Checking Throttle Position (TP) sensor - Connect VAG 1551/1552 scan tool and select "Engine Electronics" address word 01 Page 01-7 . Ignition must be switched on but engine not running. Indicated on display Rapid data transfer HELP...
Page 1109 Multiport fuel injection and ignition system Page 98 of 144 24-82 Display fields Display group 003: Load registration 1 Display xxx RPM xx.x xx.x C Indicated Engine Mass Intake air Throttle valve angle speed air flow temperature Working 800 - -46.5 to 141.0 0 - 90 range...
Page 1110 Multiport fuel injection and ignition system Page 99 of 144 24-83 Note: The displayed value is dependent on the tolerances of the Throttle Position (TP) sensor and does not correspond to the actual opening angle. The maximum permissible displayed value is 90.0 If the value does not increase uniformly: - Replace Throttle valve control module -J338-.
Page 1111 Multiport fuel injection and ignition system Page 100 of 144 24-84 Check wiring - Connect VAG 1598/18 test box to ECM wiring harness. - Connect multimeter using test leads from VW 1594 to measure resistance at test box sockets 01 and 40 and check wiring for short circuit to Ground (GND).
Page 1112 Multiport fuel injection and ignition system Page 101 of 144 24-85 If the voltage was approx. battery voltage: - Check wiring at 8-pin connector terminal 5 for short circuit to battery positive (B+) according to wiring diagram. Continuation if no voltage is present: - Check wiring between test box and 8-pin connector for open circuit according to wiring diagram.
Page 1113 Multiport fuel injection and ignition system Page 102 of 144 24-86 Basic setting, initiating Note: Only initiate "Basic Setting" function 04 when the Throttle valve control module -J338-, the Engine Control Module (ECM) -J220- or the engine has been replaced. Initiating basic setting matches the ECM to the throttle valve control module with the ignition switched on.
Page 1114 Multiport fuel injection and ignition system Page 103 of 144 24-87 Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -4- for the "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic Setting HELP...
Page 1115 Multiport fuel injection and ignition system Page 104 of 144 24-88 - Check specifications (display fields 1-4): Display fields Display group 098: Basic setting, throttle valve control module Display x.xxx V x.xxx V Text Text Indicated Throttle Throttle Operating Basic setting status Position (TP) Position (TP) mode...
Page 1116 Multiport fuel injection and ignition system Page 105 of 144 24-89 Engine Coolant Temperature (ECT) sensor -G62-, checking Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram Note:...
Page 1117 Multiport fuel injection and ignition system Page 106 of 144 24-90 Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Q- button to confirm input.
Page 1118 Multiport fuel injection and ignition system Page 107 of 144 24-91 Display fields Display group 001: Idle test Display xxxx xx.x% xxx.x C xx.x Indicated Engine Engine coolant temperature Oxygen Sensor Ignition speed (O2S) control angle Working 800 - -25.0 to 25.0% 0.0 - -46.5 to 141.0 C range...
Page 1119 Multiport fuel injection and ignition system Page 108 of 144 24-92 WARNING! The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth, and open carefully to relieve system pressure slowly.
Page 1120 Multiport fuel injection and ignition system Page 109 of 144 24-93 Checking wiring - Connect VAG 1598/18 test box to ECM wiring harness. - Disconnect 4-pin connector -1- from ECT sensor -G62- -2-. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1121 Multiport fuel injection and ignition system Page 110 of 144 24-94 - Check wiring between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 1 and test box socket Terminal 3 and test box socket Resistance: maximum 1.5 ohms ( ) - Check wiring between test box and 4-pin connector terminal 3 for short circuit to terminal 1 or to Ground...
Page 1122 Multiport fuel injection and ignition system Page 111 of 144 24-95 Intake Air Temperature (IAT) sensor - G72-, checking Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram Chilling spray (commercially available)
Page 1123 Multiport fuel injection and ignition system Page 112 of 144 24-96 Indicated on display (1-4 Display fields) Read Measuring Value Block 1 2 3 4 - Check specification for intake air temperature sensor (display field 4). Display fields Display group 003: Load registration 1 Display xxx RPM xx.x g/s...
Page 1124 Multiport fuel injection and ignition system Page 113 of 144 24-97 Evaluating display group 003 Display group: 003 Possible malfunction cause Malfunction elimination Display field: 4 -46.5 C Wiring open circuit or - Check wiring Page 24-97 short circuit to positive (B+) 141.0 C Short circuit to Ground...
Page 1125 Multiport fuel injection and ignition system Page 114 of 144 24-98 - Disconnect 2-pin connector -1- from Intake Air Temperature (IAT) sensor -G72- -2-. - Check wiring between test box and 2-pin connector for open circuit according to wiring diagram. Terminal 1 and test box socket Terminal 2 and test box socket Resistance: maximum 1.5 ohms ( )
Page 1126 Multiport fuel injection and ignition system Page 115 of 144 24-99 If the specification is not attained: - Replace IAT sensor -G72-. Continuation of check when display = ambient temperature - Remove IAT sensor (harness connector remains connected). - Read intake air temperature value in display field 4.
Page 1127 Multiport fuel injection and ignition system Page 116 of 144 24-100 Engine speed (RPM) sensor - G28-, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram Test sequence - Disconnect 3-pin connector to engine speed sensor -1-.
Page 1128 Multiport fuel injection and ignition system Page 117 of 144 24-101 - Check wiring between test box and 3-pin connector for open circuit using wiring diagram. Terminal 1 and test box socket Terminal 2 and test box socket Terminal 3 and test box socket Resistance: maximum 1.5 ohms ( ) - Additionally, check wiring for short circuits to one another.
Page 1129 Multiport fuel injection and ignition system Page 118 of 144 24-102 Speedometer Vehicle Speed Sensor (VSS) -G22- signal, checking Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram Test conditions Speedometer OK, checking:...
Page 1130 Multiport fuel injection and ignition system Page 119 of 144 24-103 Indicated on display Read Measuring Value Block HELP Input display group number XXX - Press buttons -0-, -0- and -5- for display group 005 and press -Q- button to confirm input. Indicated on display (1-4 Display Read Measuring Value Block...
Page 1131 Multiport fuel injection and ignition system Page 120 of 144 24-104 Continuation If no speed is indicated: - Disconnect 3-pin connector from vehicle speed sensor -1-. - Switch ignition on. - Connect multimeter using test leads from VW 1594 to measure voltage at terminals 1 and 3 of connector.
Page 1132 Multiport fuel injection and ignition system Page 121 of 144 24-105 If voltage was 9-14.5 volts: - Connect VAG 1598/18 test box to ECM wiring harness. - Check wiring between central electrical panel and test box socket 65 for open circuit according to wiring diagram.
Page 1133 Multiport fuel injection and ignition system Page 122 of 144 24-106 Engine Control Module (ECM) voltage supply, checking Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram Test sequence...
Page 1134 Multiport fuel injection and ignition system Page 123 of 144 24-107 Indicated on display (1-4 Read Measuring Value Block Display fields) 1 2 3 4 - Check battery voltage (display field 3). Display fields Display group 002: General engine data Display xxxx xx.xx ms...
Page 1135 Multiport fuel injection and ignition system Page 124 of 144 24-108 Evaluating display group 002 Display group: 002 Possible malfunction Malfunction elimination Display field: 3 cause If no display appears on VAG - Replace fuse Fuse 15 faulty 1551 Wiring open circuit - Check voltage supply terminal 15 Page 24-109...
Page 1136 Multiport fuel injection and ignition system Page 125 of 144 24-109 Checking voltage supply terminal 30 - Switch ignition off. - Connect VAG 1598/18 test box to ECM wiring harness. - Connect multimeter using test leads from VW 1594 to measure voltage at sockets 1 and 54: Specification: 12-14.5 volts If the specification is not attained:...
Page 1137 Multiport fuel injection and ignition system Page 126 of 144 24-110 Signal from automatic transmission, checking Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram Test sequence...
Page 1138 Multiport fuel injection and ignition system Page 127 of 144 24-111 Continuation If the display does not read as described: Indicated on display (1-4 Display Read Measuring Value Block fields) 1 2 3 4 - Check signals from automatic transmission in display field 2: Display fields Display group 008: Signals to Engine Control Module (ECM) Display...
Page 1139 Multiport fuel injection and ignition system Page 128 of 144 24-112 Signal from A/C compressor, checking Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram Check conditions...
Page 1140 Multiport fuel injection and ignition system Page 129 of 144 24-113 Test sequence Engine running at idle - Connect VAG 1551/1552 scan tool and select "Engine Electronics" address word 01 Page 01-7 Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block"...
Page 1141 Multiport fuel injection and ignition system Page 130 of 144 24-114 Display fields Display group 008: Signals to Engine Control Module (ECM) Display xxxx RPM Text Text Text Indicated Engine Driving range A/C status A/C compressor status speed status Working 800 - 6000 range Specification...
Page 1142 Multiport fuel injection and ignition system Page 131 of 144 24-115 Continuation If the display does not indicate as described: - Connect VAG 1598/18 test box to ECM wiring harness. - Check wiring between test box sockets 37 and 39 respectively and A/C for open circuit according to wiring diagram Resistance: maximum 1.5 ohms ( )
Page 1143 Multiport fuel injection and ignition system Page 132 of 144 24-116 Fuel injectors, checking Checking activation Check activation of fuel injectors Page 01-72 output Diagnostic Test Mode (DTM). Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VAG 1527B voltage tester Connector test kit VW 1594 Wiring diagram...
Page 1144 Multiport fuel injection and ignition system Page 133 of 144 24-117 - Disconnect harness connectors from fuel injectors 2-4. - Operate starter and check voltage supply for no. 1 cyl. fuel injector. LED must flicker - Repeat check on fuel injectors 2-4. If the LED does not flicker: - Switch ignition off.
Page 1145 Multiport fuel injection and ignition system Page 134 of 144 24-118 - Check wiring between fuel injector connector terminal 1 and relay panel for open circuit according to wiring diagram. Resistance: maximum 1.5 ohms ( ) - Additionally, check wires for short circuit to one another.
Page 1146 Multiport fuel injection and ignition system Page 135 of 144 24-119 Checking spray pattern and checking for leaks WARNING! DO NOT smoke or work near heaters or other fire hazards when working on fuel system. The fuel system is pressurized! Before loosening hose connections or opening the test connection, wrap a cloth around the connection.
Page 1147 Multiport fuel injection and ignition system Page 136 of 144 24-120 - Disconnect harness connector from Engine Coolant Temperature (ECT) sensor -G62-. - Set digital potentiometer VAG 1630 side A to 15 k and using test leads from VW 1594 connect to terminals 1 and 3 of disconnected harness connector.
Page 1148 Multiport fuel injection and ignition system Page 137 of 144 24-121 Fuel pressure regulator and residual pressure, checking The fuel pressure regulator controls the fuel pressure dependent upon intake manifold pressure. Special tools, testers and auxiliary items VAG 1318 pressure tester VAG 1318/10 adapter VAG 1318/11 adapter VAG 1318/16 adapter...
Page 1149 Multiport fuel injection and ignition system Page 138 of 144 24-122 Test sequence WARNING! DO NOT smoke or work near heaters or other fire hazards when working on fuel system. The fuel system is pressurized! Before loosening hose connections or opening the test connection, wrap a cloth around the connection.
Page 1150 Multiport fuel injection and ignition system Page 139 of 144 24-123 - Check for leaks and residual pressure by watching pressure drop on gauge. After 10 minutes there must be a residual pressure of at least 2 bar (29 psi). If the residual pressure drops below 2 bar (29 psi): - Start engine and run at idle speed.
Page 1151 Multiport fuel injection and ignition system Page 140 of 144 24-124 If the pressure does not drop: - Open pressure tester VAG 1318 shut-off valve, handle in direction of flow (arrow). - Start engine and run at idle speed. - After pressure has built up switch ignition off and at same time clamp- off return line (with blue arrow) on fuel rail.
Page 1152 Multiport fuel injection and ignition system Page 141 of 144 24-125 Intake air system, checking for leaks (outside air) Checking with engine leak detector spray G 001 800 A1 Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Engine leak detector spray G 001 800 A1 Note:...
Page 1153 Multiport fuel injection and ignition system Page 142 of 144 24-126 Indicated on display Read Measuring Value Block HELP Input display group number XXX - Press buttons -0-, -0- and -1- for display group 001 and press -Q- button to confirm input. Indicated on display (1-4 Display Read Measuring Value Block...
Page 1154 Multiport fuel injection and ignition system Page 143 of 144 24-127 Intake air preheating, checking Special tools, testers and auxiliary items Hand vacuum pump VAG 1390 Test conditions Temperature regulating flap vacuum unit not leaking Checking regulating flap - Remove air cleaner upper section and take out air filter element.
Page 1155 Multiport fuel injection and ignition system Page 144 of 144 24-128 Checking temperature regulator - Connect vacuum hose -3- to temperature regulator (brass connecting hose or with notch). - Start engine and run at idle speed. - Check position of regulating flap after maximum 20 seconds.
Page 1156 Multiport fuel injection and ignition system Page 1 of 37 28-1 Multiport fuel injection and ignition system Ignition system components Note: Only components which specifically relate to the ignition system are dealt with here. For other components of the fuel injection and ignition system Repair Group 24.
Page 1157 Multiport fuel injection and ignition system Page 2 of 37 28-2 Ignition system, servicing Note: Engine Control Module (ECM) - J220-* with connector Page 24-8 , item 12 . 1 - Ignition wires Check continuity 2 - Suppressor 0.6-1.4 3 - Terminal 1 4 - Terminal 5 - Ignition coil power...
Page 1158 Multiport fuel injection and ignition system Page 3 of 37 8 - Connector 3-pin 9 - Ground (GND) strap http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1159 Multiport fuel injection and ignition system Page 4 of 37 28-3 10 - Knock Sensor (KS) 1 - G61-* 11 - 20 Nm (15 ft lb) Tightening torque influences function of knock sensor 12 - Spark plug connector Use 3277 when disconnecting connecting...
Page 1160 Multiport fuel injection and ignition system Page 5 of 37 damaged 17 - Camshaft Position (CMP) sensor - G40-* Installing Page 28-8 Checking camshaft position sensor Page 28- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1161 Multiport fuel injection and ignition system Page 6 of 37 28-4 18 - Dust cap 19 - Rotor arm Marking: 0.6-1.4 20 - Distributor Check cracks signs of tracking Check contact wear Clean before installing Check carbon brush for wear and freedom movement 21 - Screening...
Page 1162 Multiport fuel injection and ignition system Page 7 of 37 28-5 Safety precautions WARNING! Be alert when working on or near the engine. High ignition secondary voltage can cause serious personal injury and damage vehicle components. DO NOT touch or disconnect ignition system wires when the engine is running or being cranked at starting RPM.
Page 1163 Multiport fuel injection and ignition system Page 8 of 37 After the work is completed, erase Diagnostic Trouble Code (DTC) memory. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1164 Multiport fuel injection and ignition system Page 9 of 37 28-6 CAUTION! BEFORE disconnecting the battery: Stop the engine. Be sure the ignition is switched OFF (also applies when connecting the battery). Failure to do so may damage the Engine Control Module (ECM).
Page 1165 Multiport fuel injection and ignition system Page 10 of 37 28-7 Technical data, spark plugs Engine code Ignition timing Checking Page 28-14 1-3-4-2 Firing order Spark plugs 101 000 044 Manufacturer's FR 8 DS designation Electrode gap 0.8 mm (0.032) Tightening torque 30 Nm (22 ft lb) Not adjustable...
Page 1166 Multiport fuel injection and ignition system Page 11 of 37 28-8 Distributor, removing and installing Special tools, testers and auxiliary items Pin wrench Matra V159 VAG 1331 torque wrench (5-50 Nm) Note: The Engine Control Module (ECM) requires the no. 1 cylinder TDC signal from the camshaft position sensor to orient the fuel injection and knock sensor systems as per firing order.
Page 1167 Multiport fuel injection and ignition system Page 12 of 37 28-9 Engine removed - Set vibration damper (V-belt pulley) to TDC no. 1 cylinder. Mark on camshaft sprocket must align with arrow on cylinder head cover. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1168 Multiport fuel injection and ignition system Page 13 of 37 28-10 Mark on distributor must align with mark on rotor arm or camshaft position sensor cover. Removing and installing distributor Test conditions Crankshaft and camshaft in no. 1 cylinder TDC position Work sequence - Remove distributor.
Page 1169 Multiport fuel injection and ignition system Page 14 of 37 28-11 - Install distributor. Pins on distributor must point toward mounting bolt threaded hole (arrow). Note: When installing, turn rotor arm slightly right of the distributor marking. When inserting, rotor arm will turn back to the marking.
Page 1170 Multiport fuel injection and ignition system Page 15 of 37 28-12 - Turn intermediate shaft sprocket with toothed drive belt in direction shown (arrow), until rotor arm aligns with markings for no. 1 cylinder on distributor housing (toothed drive belt slides over crankshaft sprocket).
Page 1171 Multiport fuel injection and ignition system Page 16 of 37 28-13 - To tighten toothed drive belt, turn tensioner with pin wrench (e.g. Matra V159) in direction shown (arrow). Drive belt is correctly tensioned if it can be turned 90 with thumb and forefinger halfway between camshaft and intermediate shaft sprockets.
Page 1172 Multiport fuel injection and ignition system Page 17 of 37 28-14 Ignition timing, checking Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Test conditions Electrical consumers switched off (radiator coolant fan must not run during the check) Air conditioner switched off Test sequence - Connect VAG 1551 scan tool ((VAG 1552) and...
Page 1173 Multiport fuel injection and ignition system Page 18 of 37 28-15 Display fields Display group 010: Ignition 1 Display xxx RPM xx.x ms xx.x xx.x Indicated Engine Engine Ignition angle Ignition angle speed load (mapped value) Working 800 - 0.0 - 0.0 - 50.0 0.0 - 40.0 BTDC...
Page 1174 Multiport fuel injection and ignition system Page 19 of 37 28-16 Misfire detection, checking Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Test sequence - Connect VAG 1551 scan tool ((VAG 1552) and select "Engine Electronics"...
Page 1175 Multiport fuel injection and ignition system Page 20 of 37 28-17 Display fields Display group 110: Misfire detection 1 Display x.xx ms xxxxxxxx Indicated Engine Misfiring Misfiring adversely Misfiring load adversely affecting three way recognition affecting exhaust catalytic converter status gas (total) (total) Working...
Page 1176 Multiport fuel injection and ignition system Page 21 of 37 28-18 Evaluating display group 110 Display group: Possible malfunction Malfunction elimination Display field: 2 cause More than 25 - Check ignition coil Page 28-30 Ignition coil faulty - Checking components of ignition system Ignition wire faulty Page 28-1 Spark plug faulty...
Page 1177 Multiport fuel injection and ignition system Page 22 of 37 28-19 Ignition timing control, checking Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable Test conditions Electrical consumers switched off (radiator coolant fan must not run during the check) Air conditioner switched off Engine oil temperature at least 80 C (176 Test sequence...
Page 1178 Multiport fuel injection and ignition system Page 23 of 37 28-20 Indicated on display (1-4 Display fields) Read Measuring Value Block - Check measured values for ignition timing control (display fields 1-4). Display fields Display group 010: Ignition 1 Display xxx RPM xx.x ms xx.x...
Page 1179 Multiport fuel injection and ignition system Page 24 of 37 28-21 Continuation - Check engine operating conditions Page 24- - Check throttle valve control module Page 24- - Check knock sensor and knock control Page 28-25 If the specification is again not attained: - Replace Engine Control Module (ECM) -J220- Page 24-8 , item 12 .
Page 1180 Multiport fuel injection and ignition system Page 25 of 37 28-22 Camshaft Position (CMP) sensor, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram Test sequence - Disconnect 3-pin connector from camshaft position sensor.
Page 1181 Multiport fuel injection and ignition system Page 26 of 37 28-23 If the specification is not attained: - Connect VAG 1598/18 test box to Engine Control Module (ECM) wiring harness. - Check wiring between test box and 3-pin connector for open circuit according to wiring diagram.
Page 1182 Multiport fuel injection and ignition system Page 27 of 37 28-24 - Additionally check all wires for short circuit to each other. Terminal 3 and test box socket 44 Terminal 3 and test box socket 56 Terminal 2 and test box socket 56 Specification: ohms ( ) If no wiring malfunction is detected and voltage...
Page 1183 Multiport fuel injection and ignition system Page 28 of 37 28-25 Knock Sensor (KS) and knock control, checking Special tools, testers and auxiliary items VAG 1551/1552 scan tool with VAG 1551/3 adapter cable VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Wiring diagram Test sequence...
Page 1184 Multiport fuel injection and ignition system Page 29 of 37 28-26 Note: The check must be carried out during a test drive as knock control is not active with an engine load exceeding 3 ms. - Perform test drive and observe specification for knock control on display (second technician necessary).
Page 1185 Multiport fuel injection and ignition system Page 30 of 37 28-27 Evaluating display group 045 Display group: 045 Malfunction Display fields: 1-4 Possible malfunction elimination cause All cylinders more - Continuation Page 28-28 Knock sensor faulty than 12 Connector corroded Knock sensor - Loosen knock sensor and tighten to 20 incorrectly...
Page 1186 Multiport fuel injection and ignition system Page 31 of 37 28-28 Continuation - Disconnect blue 3-pin connector -2- from Knock Sensor (KS) 1 -G61- -1-. - Connect multimeter with test leads from VW 1594 to measure resistance between terminals 1 and 2, 1 and 3, and 2 and 3 on knock sensor connector.
Page 1187 Multiport fuel injection and ignition system Page 32 of 37 28-29 - Check wiring between test box and 3-pin connector for open circuit according to wiring diagram. Terminal 1 and test box socket Terminal 2 and test box socket Terminal 3 and test box socket Resistance: max.
Page 1188 Multiport fuel injection and ignition system Page 33 of 37 28-30 Ignition coil, checking Special tools, testers and auxiliary items Multimeter (Fluke 83 or equivalent) Connector test kit VW 1594 Test sequence - Disconnect connector and ignition wire from ignition coil -N152-. - Connect multimeter with test leads from VW 1594 to measure resistance.
Page 1189 Multiport fuel injection and ignition system Page 34 of 37 28-31 Ignition coil power output stage, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VAG 1527B voltage tester Connector test kit VW 1594 Wiring diagram Checking voltage supply - Disconnect 3-pin connector from...
Page 1190 Multiport fuel injection and ignition system Page 35 of 37 28-32 - Check wiring between 3-pin connector and relay panel for open circuit using wiring diagram. Terminal 1 and relay panel Terminal 3 and relay panel Resistance: max. 1.5 ohms ( ) If no wiring malfunction is detected and voltage was present between terminals 1 and 3: - Replace Ignition coil -N152-...
Page 1191 Multiport fuel injection and ignition system Page 36 of 37 28-33 - Operate starter and check ignition signal from ECM. LED must flicker - Switch ignition off. If the LED does not flicker: - Connect VAG 1598/18 test box to ECM wiring harness.
Page 1192 Multiport fuel injection and ignition system Page 37 of 37 28-34 If the voltage supply and activation is OK.: - Reconnect 3-pin harness connector and ignition wire to ignition coil. - Connect LED voltage tester with test leads to terminals 1 and 15 on ignition coil. CAUTION! During the following test do not touch the terminals of the ignition coil or test cables.
Page 1195 2.0 Liter 4-Cyl. 2V Generic Scan Tool Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1996-1997 20 - Fuel Supply Fuel supply system components, removing and installing Fuel filter and fuel tank with attaching parts, removing and installing Safety precautions when working on fuel supply system Rules of cleanliness Fuel pump, removing and installing Fuel Pump (FP), checking...
Page 1196 Function tests Oxygen sensor and oxygen sensor regulation before catalytic converter, checking Oxygen sensor and oxygen sensor regulation behind catalytic converter, checking Intake air pre-heating, checking Engine Control Module (ECM) Function Voltage supply for Engine Control Module (ECM), checking Engine Control Module (ECM), replacing Additional signals, Checking Speed signal, checking 26 - Exhaust system, Emission controls...
Page 1197 Selector lever mechanism, (vehicles with ignition key removal lock), disassembling and assembling Selector lever, (vehicles with ignition key removal lock), disassembling and assembling Locking cable (vehicles with ignition key removal lock), removing and installing Locking cable (vehicles with ignition key removal lock), adjusting Selector lever cable, checking and adjusting Ignition key removal lock (vehicles with ignition key removal lock), checking 38 - Automatic Transmission - Gears, Hydraulic controls...
Page 1198 Diagnostic Trouble Code (DTC) tables: SAE P0xxx-DTCs SAE P1xxx-DTCs SAE P2xxx-DTCs SAE P3xxx-DTCs...
Page 1199 Fuel supply system components, removing and installing Page 1 of 29 20-1 Fuel supply system components, removing and installing Note: Hose connections are secured with click-type clamps, spring-type clamps or open clips with insert. Fuel hoses at engine must only be secured with spring-type clamps.
Page 1200 Fuel supply system components, removing and installing Page 2 of 29 20-2 Fuel filter and fuel tank with attaching parts, removing and installing Note: Make sure the supply or return lines do not come into contact with the fuel tank after all work on the fuel pump or the fuel gauge...
Page 1201 Fuel supply system components, removing and installing Page 3 of 29 20-3 5 - O-ring Replace damaged 6 - Vent valve Checking Fig. 2 7 - Union nut, 60 Nm 8 - Expansion tank Version shown: Wagon sedan, simpler expansion tank 9 - Vent line Filler...
Page 1202 Fuel supply system components, removing and installing Page 4 of 29 20-4 11 - Return hose Blue Check secure seating From fuel return line at fuel distributor Page 24-14 Item 35 12 - Union nut, 60 Nm wrench 3217 to remove install 13 - Flange...
Page 1203 Fuel supply system components, removing and installing Page 5 of 29 install, place into opening of fuel tank when dry Only coat with fuel when installing Fuel Pump (FP) flange http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1204 Fuel supply system components, removing and installing Page 6 of 29 20-5 16 - Return hose Check secure seating 17 - Sender for fuel gauge 18 - Fuel pump (FP) -G- Removing installing Page 20-11 Checking Fuel Pump (FP) Page 20- 19 - Tension strap Note...
Page 1205 Fuel supply system components, removing and installing Page 7 of 29 20-6 23 - Supply line Black Check secure seating To fuel supply line at fuel distributor Page 24-14 Item 34 24 - Fuel filter Installation position: (Arrow) points in direction of flow 25 - Screw clip...
Page 1206 Fuel supply system components, removing and installing Page 8 of 29 unclip valve upward and lift out. Checking valve for throughput Valve vertical: open, Valve tilted 45 : closed http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1207 Fuel supply system components, removing and installing Page 9 of 29 20-7 Fig. 1 Installation position of Fuel Pump (FP) flange Mark on flange must align with mark on fuel tank Note: After installing Fuel Pump (FP) unit flange, check whether supply, return and ventilation lines are still clipped in at fuel tank.
Page 1208 Fuel supply system components, removing and installing Page 10 of 29 20-8 Safety precautions when working on fuel supply system WARNING! Observe the following for all installations, especially in engine compartment due to lack of room: Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is...
Page 1209 Fuel supply system components, removing and installing Page 11 of 29 20-9 Before starting work, switch on exhaust extraction system and place an extraction hose close to the installation opening of fuel tank to extract escaping fuel fumes. If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m...
Page 1210 Fuel supply system components, removing and installing Page 12 of 29 20-10 Rules of cleanliness When working on the fuel supply or fuel injection systems, the following "5 rules of cleanliness" should be carefully observed: Thoroughly clean all connections and the surrounding area before disconnecting.
Page 1211 Fuel supply system components, removing and installing Page 13 of 29 20-11 Fuel pump, removing and installing Recommended special tools and equipment 3217 Ring nut spanner V.A.G1332 Torque wrench (40 to 200 Observe safety precautions Page 20- Observe rules for cleanliness Page 20-10 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 1212 Fuel supply system components, removing and installing Page 14 of 29 20-12 Requirements Parking brake must be engaged or else daylight driving lights will be switched on. Ignition switched off. Fuel tank must be drained. Removing - First determine whether a coded radio is installed.
Page 1213 Fuel supply system components, removing and installing Page 15 of 29 20-13 WARNING! The fuel or fuel lines in fuel system can become very hot (danger of scalding)! In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!
Page 1214 Fuel supply system components, removing and installing Page 16 of 29 20-14 Installing Installation of the fuel pump is the reverse order of removal. Note: When inserting Fuel Pump (FP) unit into fuel tank, be sure not to bend sender for fuel gauge. Coat seal with fuel when installing Fuel Pump (FP).
Page 1215 Fuel supply system components, removing and installing Page 17 of 29 20-15 Fuel Pump (FP), checking Recommended special tools and equipment 3217 Ring nut spanner V.A.G 1318 Pressure gauge V.A.G 1318/1 Hose V.A.G 1318/10 Adapter V.A.G 1318/11 Adapter V.A.G1332 Torque wrench (40 to 200 Nm) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 1216 Fuel supply system components, removing and installing Page 18 of 29 20-16 V.A.G1348/3A Remote control with V.A.G1348/3- 2 adapter cable V.A.G1527B Voltage tester V.A.G 1594 C Connector test kit V.A.G1715 Multimeter VAS5024A Assembly tool for spring-type clamps Not illustrated: Measuring container Wiring diagram...
Page 1217 Fuel supply system components, removing and installing Page 19 of 29 20-17 Test requirements Fuse no. 18 for Fuel Pump (FP) must be OK. Battery voltage must be at least 11.5 volts. Ground (GND) connections between engine, transmission, and chassis must be OK. All electrical consumers such as lights and rear window defroster must be switched off.
Page 1218 Fuel supply system components, removing and installing Page 20 of 29 20-18 If Fuel Pump (FP) does not start up: - Remove Fuel Pump (FP) Relay -J17- from relay carrier (relay position 12). Note: Remove battery Ground (GND) strap if tools are necessary for removal of relays or control modules from the relay carrier.
Page 1219 Fuel supply system components, removing and installing Page 21 of 29 20-19 If Fuel Pump (FP) does not run: - Remove luggage compartment floor cover. - Disconnect connector from flange on fuel tank. - Connect diode test lamp to outer terminals of connector.
Page 1220 Fuel supply system components, removing and installing Page 22 of 29 20-20 If there are no open circuits: - Fuel Pump (FP) faulty, replace Fuel Pump (FP) Page 20-11 , Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4:...
Page 1221 Fuel supply system components, removing and installing Page 23 of 29 20-21 WARNING! The fuel or fuel lines in fuel system can become very hot (danger of scalding)! In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!
Page 1222 Fuel supply system components, removing and installing Page 24 of 29 20-22 - Operate remote control. Slowly close shut-off valve until on pressure gauge 3 bar positive pressure is indicated. Do not change position of shut-off valve any more. - Empty measuring container. - Delivery rate of Fuel Pump (FP) is dependent on battery voltage.
Page 1223 Fuel supply system components, removing and installing Page 25 of 29 20-23 If minimum delivery rate is not obtained: - Check fuel lines for possible restrictions (kinks) or clogging. - Disconnect supply hose -1- from fuel filter input. WARNING! The fuel or fuel lines in fuel system can become very hot (danger of scalding)! In addition, the fuel system is under pressure!Before opening the system, place...
Page 1224 Fuel supply system components, removing and installing Page 26 of 29 20-24 If minimum delivery rate is obtained now: - Replace fuel filter Page 20-6 item 24 , removing and installing fuel tank with attachments and fuel filter If minimum delivery rate is still not obtained: - Remove fuel delivery unit Page 20-11 check filter strainer for dirt.
Page 1225 Fuel supply system components, removing and installing Page 27 of 29 20-25 Current pick-up of Fuel Pump (FP), checking - Connect multimeter with current probe to red/yellow wire of wiring harness. - Start engine and let run at idle. - Measure Fuel Pump (FP) current draw.
Page 1226 Fuel supply system components, removing and installing Page 28 of 29 20-26 Fuel Pump (FP) check-valve, checking Test requirements Remote control connected Pressure gauge is still connected. Test sequence Note: This test also checks the connections of the fuel supply line from Fuel Pump (FP) unit to connection point of pressure gauge for proper seal.
Page 1227 Fuel supply system components, removing and installing Page 29 of 29 20-27 WARNING! Danger of spray when opening shut-off valve. Hold container in front of open connection on pressure gauge. - Observe pressure drop on pressure gauge. Pressure must not fall below 2 bar. If pressure drops further: - Check line connections for proper seal.
Page 1228 EVAP canister system Page 1 of 10 20-28 EVAP canister system Note: Hose connections are secured with screw-type clamps, spring-type clamps or tensioning clamps. Always replace tensioning clamps with spring- type clamps or screw-type clamps. Fuel hoses at engine must only be secured with spring-type clamps.
Page 1229 EVAP canister system Page 2 of 10 20-29 EVAP canister system components, removing and installing 1 - Connector Black, 2- 2 - Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Black Installation position: (Arrow) points in direction of flow Checking Page 20-34 3 - Bracket...
Page 1230 EVAP canister system Page 3 of 10 Check secure seating From gravity valve at fuel tank Page 20-6 item 27 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1231 EVAP canister system Page 4 of 10 20-30 7 - EVAP canister Component location: in wheelhousing, right front remove, press securing tab in direction (arrow) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1232 EVAP canister system Page 5 of 10 20-31 Fuel tank ventilation, checking Recommended special tools and equipment V.A.G 1368 Vacuum tester V.A.G1390 Hand vacuum pump Test required Ignition switched off http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1233 EVAP canister system Page 6 of 10 20-32 Test sequence - Remove air filter Page 24-7 , item - Disconnect bleeder hose to EVAP canister -4- at Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- (-6-). - Connect hand vacuum pump to hose.
Page 1234 EVAP canister system Page 7 of 10 20-33 If no vacuum builds up: - Remove fuel filler cap from fuel filler tube. - Connect hand vacuum pump to vacuum tester connection -B-. - Set vacuum tester to position -A/B-. - Operate Vacuum pump several times.
Page 1235 EVAP canister system Page 8 of 10 20-34 Evaporative Emission (EVAP) canister purge regulator valve 1, checking Solenoid valve is closed when no voltage is present. Recommended special tools and equipment V.A.G1526 Multimeter or V.A.G1715 multimeter V.A.G1594 Connector test kit Wiring diagram http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 1236 EVAP canister system Page 9 of 10 20-35 Test requirements The respective fuses of Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- must be OK: Electrical Wiring Diagrams, Troubleshooting & Component Locations Ground (GND) connections between engine, transmission and chassis must be OK. Ignition switched off.
Page 1237 EVAP canister system Page 10 of 10 20-36 If specified value is obtained: - Check wires according to wiring diagram Page 20-36 Checking wiring - Connect test box to control module wiring harness Page ST-11 , connect test box for wiring test.
Page 1238 Accelerator Pedal (AP) cable, adjusting Page 1 of 3 20-37 Accelerator Pedal (AP) cable, adjusting Vehicles with manual transmission Requirement Ignition switched off Procedure - Press accelerator pedal to Wide Open Throttle (WOT) position. - Adjust accelerator pedal cable via swapping of positioning clip at support bracket so that Wide Open Throttle (WOT) position is just reached on cable pulley of throttle valve control module.
Page 1239 Accelerator Pedal (AP) cable, adjusting Page 2 of 3 20-38 Vehicles with automatic transmission Recommended special tools and equipment Spacer piece 15 mm V.A.G1526 Multimeter or V.A.G1715 multimeter V.A.G1594 Connector test kit Requirement Ignition switched off Procedure Test sequence - Spacer piece -1-, a = 15 mm, clamp between accelerator pedal -2- and stop -3- and hold accelerator pedal firmly in this position.
Page 1240 Accelerator Pedal (AP) cable, adjusting Page 3 of 3 20-39 - Adjust accelerator pedal cable via swapping of positioning clip at support bracket so that Wide Open Throttle (WOT) position is reached on throttle valve lever. - Release accelerator pedal. - Connect hand multimeter with adapter cables to Kick Down Switch - F8-.
Page 1241 Motronic fuel injection and ignition system Page 1 of 37 24-1 Motronic fuel injection ignition system Overview of component locations Note: Components marked with * are tested via On Board Diagnostic (OBD) Page ST-22 Diagnostic mode 3: Check DTC memory. 1 - Evaporative Emission (EVAP)
Page 1242 Motronic fuel injection and ignition system Page 2 of 37 module - J338-* 4 - Engine Control Module (ECM)* (control module for Motronic Engine Control Module (ECM) - J220-) Component location: in plenum chamber 68-pin connector Checking voltage supply Page 24- Replace Page 24-105...
Page 1243 Motronic fuel injection and ignition system Page 3 of 37 24-2 5 - 4-pin harness connector Brown Heated Oxygen Sensor (HO2S) 2 -G108- oxygen sensor heater 6 - 4-pin harness connector Black Heated Oxygen Sensor (HO2S) - G39- and oxygen sensor heater 7 - Intake Air...
Page 1244 Motronic fuel injection and ignition system Page 4 of 37 Sensor (VSS) -G22- Checking Page 24-106 checking speed signal http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1245 Motronic fuel injection and ignition system Page 5 of 37 24-3 Engine Coolant Temperature (ECT) Sensor - G62-* Black Engine Control Module (ECM) With Engine Coolant Temperature (ECT) Sensor (G2) necessary, release pressure in cooling system before removing 11 - Central harness connector 12 - 3-pin...
Page 1246 Motronic fuel injection and ignition system Page 6 of 37 Engine Speed (RPM) Sensor - G28- 14 - Engine Speed (RPM) Sensor - G28-* 15 - Secondary Injection (AIR) pump motor - V101-* Page 26-15 item 12 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1247 Motronic fuel injection and ignition system Page 7 of 37 24-4 16 - Distributor with Camshaft Position (CMP) Sensor - G40-* Page 28-5 item 17 17 - Fuel injectors (- N30- through - N33-)* 18 - Knock Sensor (KS) 1 - G61-* Page 28-4...
Page 1248 Motronic fuel injection and ignition system Page 8 of 37 24-5 General Notes on Fuel Injection Servicing ignition Page 28-1 Note: Engine Control Module (ECM) is equipped with On Board Diagnostic (OBD). Always check DTC memory first, before performing repairs or troubleshooting.
Page 1249 Motronic fuel injection and ignition system Page 9 of 37 24-6 VAS5024A spring clip installation tool is recommended for installing spring-type clips. Components marked with * are tested via On Board Diagnostic (OBD) Page ST-22 , Diagnostic mode 3: Check DTC memory. It is possible that the control module will recognize a malfunction and store a DTC during some tests.
Page 1250 Motronic fuel injection and ignition system Page 10 of 37 24-7 Fuel injector parts, servicing 1 - Air filter Disassembling assembling Page 24-19 2 - Connector 4 pin For Mass Air Flow (MAF) Sensor - G70- 3 - Ventilation line Check for secure seating...
Page 1251 Motronic fuel injection and ignition system Page 11 of 37 Secure with spring clamps 5 - Pressure regulator valve for crankshaft housing ventilation http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1252 Motronic fuel injection and ignition system Page 12 of 37 24-8 6 - Connector 8-pin Throttle Valve Control Module - J338- 7 - Upper part of intake manifold First tighten at lower section of intake manifold, then tighten both rear supports item Disassembling...
Page 1253 Motronic fuel injection and ignition system Page 13 of 37 Checking Page 24-36 9 - Connector 68-pin Switch ignition off before disconnecting or connecting connector http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1254 Motronic fuel injection and ignition system Page 14 of 37 24-9 10 - Securing plate Motronic Engine Control Module (ECM) - J220- 11 - 10 Nm 12 - Motronic Engine Control Module (ECM) - J220-* Component location: In plenum chamber, right side For fuel injection...
Page 1255 Motronic fuel injection and ignition system Page 15 of 37 (OBD) Checking voltage supply Page 24- Replace Page 24-105 13 - From brake booster 14 - To A/C system 15 - Retaining clip Check secure fitting http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1256 Motronic fuel injection and ignition system Page 16 of 37 24-10 16 - O-ring Replace damaged Engine Coolant Temperature (ECT) Sensor - G62-* Engine Control Module (ECM) 4 pin With Engine Coolant Temperature (ECT) Sensor -G2- necessary, release pressure in cooling system before removing...
Page 1257 Motronic fuel injection and ignition system Page 17 of 37 (Cylinder 1 Fuel Injector - N30- through Cylinder 4 Fuel Injector - N33-) 20 - 20 Nm 21 - Support Between upper part of intake manifold cylinder head http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1258 Motronic fuel injection and ignition system Page 18 of 37 24-11 22 - Gasket Always replace 23 - Lower part of intake manifold Disassembling assembling Page 24-17 24 - Engine speed (RPM) sensor - G28-* Checking Page 24-61 25 - Spacer ring http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 1259 Motronic fuel injection and ignition system Page 19 of 37 24-12 26 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130- bank 1*, 50 Nm Component location: In rear catalytic converter Only grease threads with G 052 112 A3 locking compound,...
Page 1260 Motronic fuel injection and ignition system Page 20 of 37 heater for Oxygen Sensor (O2S) behind Three Catalytic Converter (TWC) Page 24- Check Oxygen Sensor (O2S) oxygen sensor control behind Three Catalytic Converter (TWC) Page 24- 27 - 4-pin harness connector Brown Heated...
Page 1261 Motronic fuel injection and ignition system Page 21 of 37 24-13 28 - Heated Oxygen Sensor (HO2S) 1 - G39-*, 50 Component location: in front exhaust pipe Only grease threads with G 052 112 A3 locking compound, do NOT allow locking compound to get into...
Page 1262 Motronic fuel injection and ignition system Page 22 of 37 Three Catalytic Converter (TWC) Page 24- Check Oxygen Sensor (O2S) oxygen sensor control before Three Catalytic Converter (TWC) Page 24- 29 - 4-pin harness connector Black Heated Oxygen Sensor (HO2S) - G39- and oxygen sensor...
Page 1263 Motronic fuel injection and ignition system Page 23 of 37 24-14 30 - Deflector 31 - To crankcase 32 - Hose To warm collector plate at exhaust manifold 33 - Retaining ring 34 - Supply hose White arrow Secure with spring clamps From fuel...
Page 1264 Motronic fuel injection and ignition system Page 24 of 37 Page 20-4 item 11 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...
Page 1265 Motronic fuel injection and ignition system Page 25 of 37 24-15 Intake manifold, upper part, disassembling assembling 1 - M6 = 10 Nm, M8 = 20 Nm 2 - Throttle valve control module - J338-* 8-pin connector Components of throttle valve control module - J338-...
Page 1266 Motronic fuel injection and ignition system Page 26 of 37 Adjusting accelerator pedal cable Page 20- 3 - Bracket 4 - Mounting bracket accelerator pedal cable http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004...

Volkswagen Passat 1995 Official Factory Repair Manual

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