2.8 Liter VR6 2V Generic Scan Tool Fuel Injection & Ignition,
Engine Code(s): AAA m.y. 1996-1997
20 - Fuel Supply
Fuel sup...
Oxygen sensor heater for oxygen sensors behind Three Way
Catalytic Converter (TWC), checking
Mass Air Flow (MAF) sensor, c...
28 - Ignition/Glow plug system
Ignition, servicing
General notes on ignition system
Ignition components, removing and inst...
Readiness code
Function
Readiness code, reading
Readiness code, generating
DTC tables
SAE P0xxx-DTCs
SAE P1xxx-DTCs
Fuel supply system components, removing and installing

Page 1 of 27
20-1

Fuel supply system
components, removing and
ins...
Fuel supply system components, removing and installing

Page 2 of 27
20-2

Fuel tank with
attachments and fuel
filter, rem...
Fuel supply system components, removing and installing

Page 3 of 27
20-3

5 - O-ring
Replace if damaged
6 - Bleeder valve...
Fuel supply system components, removing and installing

Page 4 of 27
20-4

11 - Return hose
Blue
Check for secure fitting
...
Fuel supply system components, removing and installing

Page 5 of 27
20-5

16 - Return hose
Check for secure fitting
17 - ...
Fuel supply system components, removing and installing

Page 6 of 27
20-6

23 - Supply line
Black
Check for secure fitting...
Fuel supply system components, removing and installing

Page 7 of 27
20-7

Fig. 1

Installation position of fuel pump flan...
Fuel supply system components, removing and installing

Page 8 of 27
20-8

Safety precautions when working on
fuel supply
...
Fuel supply system components, removing and installing

Page 9 of 27
20-9

Before starting work, switch on exhaust
extract...
Fuel supply system components, removing and installing

Page 10 of 27
20-10

Rules of cleanliness
When working on the fuel...
Fuel supply system components, removing and installing

Page 11 of 27
20-11

Fuel Pump (FP), removing and installing
Recom...
Fuel supply system components, removing and installing

Page 12 of 27
20-12

Observe safety precautions
Observe rules for ...
Fuel supply system components, removing and installing

Page 13 of 27
20-13

WARNING!
The fuel or fuel lines in fuel syste...
Fuel supply system components, removing and installing

Page 14 of 27
20-14

Installing
Installation of the fuel pump is t...
Fuel supply system components, removing and installing

Page 15 of 27
20-15

Fuel pump, checking
Recommended special tools...
Fuel supply system components, removing and installing

Page 16 of 27
20-16

V.A.G 1348/3A remote
control with V.A.G 1348/...
Fuel supply system components, removing and installing

Page 17 of 27
20-17

Test requirements
Fuse no. 18 for Fuel Pump (...
Fuel supply system components, removing and installing

Page 18 of 27
20-18

If Fuel Pump (FP) does not start up:
- Remove...
Fuel supply system components, removing and installing

Page 19 of 27
20-19

If Fuel Pump (FP) does not run:
- Remove lugg...
Fuel supply system components, removing and installing

Page 20 of 27
20-20

If there are no open circuits:
- Fuel Pump (F...
Fuel supply system components, removing and installing

Page 21 of 27
20-21

WARNING!
The fuel or fuel lines in fuel syste...
Fuel supply system components, removing and installing

Page 22 of 27
20-22

- Operate remote control. Slowly close shut-o...
Fuel supply system components, removing and installing

Page 23 of 27
20-23

If minimum delivery rate is not obtained:
- C...
Fuel supply system components, removing and installing

Page 24 of 27
20-24

If minimum delivery rate is now obtained:
- R...
Fuel supply system components, removing and installing

Page 25 of 27
20-25

Current pick-up of Fuel Pump (FP), checking
-...
Fuel supply system components, removing and installing

Page 26 of 27
20-26

Fuel Pump (FP) check-valve, checking
Test req...
Fuel supply system components, removing and installing

Page 27 of 27
20-27

WARNING!
Danger of spray when opening shut-of...
EVAP canister system

Page 1 of 22
20-28

EVAP canister system
Note:
Hose connections are secured with screw-type
clamps, ...
EVAP canister system

Page 2 of 22
20-29

EVAP canister system,
components, removing
and installing (vehicles
without Leak...
EVAP canister system

Page 3 of 22
20-30

5 - Bracket
At lower section of air
filter
6 - Upper part of intake
manifold
7 -...
EVAP canister system

Page 4 of 22
20-31

Fig. 1

Installed position of vent line on upper
section of intake manifold

Mar...
EVAP canister system

Page 5 of 22
20-32

EVAP canister system
components, removing
and installing (vehicles
with Leak Det...
EVAP canister system

Page 6 of 22
20-33

4 - Retaining ring
For Evaporative
Emission (EVAP)
canister purge
regulator valv...
EVAP canister system

Page 7 of 22
20-34

11 - Leak Detection Pump
(LDP) -V144-*
3-pin connector, black
Checking
46

Page ...
EVAP canister system

Page 8 of 22
20-35

Fig. 1

Installed position of vent line on upper
section of intake manifold

Mar...
EVAP canister system

Page 9 of 22
20-36

Fuel tank ventilation, checking (vehicles
without Leak Detection Pump)
Recommend...
EVAP canister system

Page 10 of 22
20-37

Test sequence
- Remove air filter Page 24-19 , disassembling
and assembling air...
EVAP canister system

Page 11 of 22
20-38

If vacuum builds up:
- Check breather connection -5- at EVAP canister
-4- for s...
EVAP canister system

Page 12 of 22
20-39

If no vacuum builds up:
- Screw fuel filler cap on fuel filler tube.
- Operate ...
EVAP canister system

Page 13 of 22
20-40

EVAP canister system for proper seal,
checking (vehicles with Leak Detection
Pu...
EVAP canister system

Page 14 of 22
20-41

Checking proper seal
If a small or large leak was recognized during the
test of...
EVAP canister system

Page 15 of 22
20-42

If malfunction persists:
- Remove EVAP canister and check for cracks
and leaks,...
EVAP canister system

Page 16 of 22
20-43

Evaporative Emission (EVAP) canister
purge regulator valve 1, checking
Solenoid...
EVAP canister system

Page 17 of 22
20-44

Test sequence
- Disconnect 2-pin connector from Evaporative
Emission (EVAP) Can...
EVAP canister system

Page 18 of 22
20-45

If specified value is obtained:
- Check wires according to wiring diagram
Page ...
EVAP canister system

Page 19 of 22
20-46

Leak Detection Pump (LDP), checking
Recommended special tools and equipment
V.A...
EVAP canister system

Page 20 of 22
20-47

Work sequence
- Remove right rear wheelhousing liner.
- Disconnect 3-pin connec...
EVAP canister system

Page 21 of 22
20-48

Checking wiring
- Connect test box to control module wiring
harness Page ST-10 ...
EVAP canister system

Page 22 of 22
20-49

- Erase DTC memory of Engine Control Module
(ECM) Page ST-25 , Diagnostic mode ...
Accelerator Pedal (AP) cable, adjusting

Page 1 of 4
20-50

Accelerator Pedal (AP) cable,
adjusting
Vehicles with manual t...
Accelerator Pedal (AP) cable, adjusting

Page 2 of 4
20-51

Vehicles with automatic transmission
Recommended special tools...
Accelerator Pedal (AP) cable, adjusting

Page 3 of 4
20-52

- Spacer piece -1-,
a = 15 mm, clamp between accelerator pedal...
Accelerator Pedal (AP) cable, adjusting

Page 4 of 4
20-53

- Connect hand multimeter with adapter cables to
Kick Down Swi...
Motronic fuel injection and ignition system

Page 1 of 26
24-1

Motronic fuel
injection and
ignition system
Component loca...
Motronic fuel injection and ignition system

Page 2 of 26
24-2

3 - Intake hose
With Positive
Crankcase Ventilation
(PCV) ...
Motronic fuel injection and ignition system

Page 3 of 26
24-3

10 - Engine Coolant
Temperature (ECT)
Sensor -G62-*
Blue, ...
Motronic fuel injection and ignition system

Page 4 of 26
24-4

17 - Fuel injector (-N30- to N33-, -N83-, -N84-)*
Checking...
Motronic fuel injection and ignition system

Page 5 of 26
24-5

General Notes on Fuel Injection
Servicing ignition

Page 2...
Motronic fuel injection and ignition system

Page 6 of 26
24-6

VAS 5024A spring-type clip pliers is
recommended for insta...
Motronic fuel injection and ignition system

Page 7 of 26
24-7

Fuel injection system
components, removing
and installing
...
Motronic fuel injection and ignition system

Page 8 of 26
24-8

5 - Oxygen Sensor (O2S)
Behind Three Way
Catalytic Convert...
Motronic fuel injection and ignition system

Page 9 of 26
24-9

6 - Heated Oxygen Sensor
(HO2S) 1 -G39-*, 50 Nm
Component ...
Motronic fuel injection and ignition system

Page 10 of 26
24-10

7 - Engine Coolant
Temperature (ECT)
Sensor -G62-*
Blue,...
Motronic fuel injection and ignition system

Page 11 of 26
24-11

13 - Bracket
For harness connector
for oxygen sensors
an...
Motronic fuel injection and ignition system

Page 12 of 26
24-12

Fuel distributor with fuel
injectors, disassembling
and ...
Motronic fuel injection and ignition system

Page 13 of 26
24-13

6 - Fuel distributor
7 - 10 Nm
8 - 25 Nm
9 - Lower part ...
Motronic fuel injection and ignition system

Page 14 of 26
24-14

15 - Connector
2-pin
For fuel injector (-N30to -N33-, -N...
Motronic fuel injection and ignition system

Page 15 of 26
24-15

Throttle valve control
module, removing and
installing
1...
Motronic fuel injection and ignition system

Page 16 of 26
24-16

7 - Ventilation hose
Check for secure fitting
Note insta...
Motronic fuel injection and ignition system

Page 17 of 26
24-17

10 - Gasket
Always replace
11 - Pivot
For accelerator pe...
Motronic fuel injection and ignition system

Page 18 of 26
24-18

Fig. 1

Installed position of vent line on upper
section...
Motronic fuel injection and ignition system

Page 19 of 26
24-19

Air filter, disassembling
and assembling
1 - Upper part ...
Motronic fuel injection and ignition system

Page 20 of 26
24-20

8 - Mass Air Flow (MAF)
Sensor -G70-*
Checking
33

Page ...
Motronic fuel injection and ignition system

Page 21 of 26
24-21

12 - Crankcase vent valve
13 - To upper part of intake
m...
Motronic fuel injection and ignition system

Page 22 of 26
24-22

Safety precautions
CAUTION!
Observe the following for al...
Motronic fuel injection and ignition system

Page 23 of 26
24-23

If special testing equipment is required during
road tes...
Motronic fuel injection and ignition system

Page 24 of 26
24-24

If engine is to be cranked at starting RPM
without start...
Motronic fuel injection and ignition system

Page 25 of 26
24-25

Rules of cleanliness
When working on the fuel supply or ...
Motronic fuel injection and ignition system

Page 26 of 26
24-26

Technical data
Engine Code

AAA

Idle speed1)

650 to 75...
Engine components,checking

Page 1 of 59
24-27

Engine components,checking
Oxygen sensor heater for oxygen
sensor before T...
Engine components,checking

Page 2 of 59
24-28

Test sequence
- Disconnect 4-pin harness connector (black) to
Heated Oxyge...
Engine components,checking

Page 3 of 59
24-29

If specified value is obtained:
- Check Ground (GND) activation of oxygen
...
Engine components,checking

Page 4 of 59
24-30

Oxygen sensor heater for oxygen
sensors behind Three Way Catalytic
Convert...
Engine components,checking

Page 5 of 59
24-31

Test sequence
- Disconnect 4-pin harness connector (brown) to
Heated Oxyge...
Engine components,checking

Page 6 of 59
24-32

If specified value is obtained:
- Check Ground (GND) activation of oxygen
...
Engine components,checking

Page 7 of 59
24-33

Mass Air Flow (MAF) sensor, checking
Recommended special tools and equipme...
Engine components,checking

Page 8 of 59
24-34

Parking brake must be engaged or else
daylight driving lights will be swit...
Engine components,checking

Page 9 of 59
24-35

- Check specified value of air flow quantity at
Mass Air Flow (MAF) Sensor...
Engine components,checking

Page 10 of 59
24-36

Voltage supply for Mass Air Flow (MAF)
sensor, checking
- Disconnect 4-pi...
Engine components,checking

Page 11 of 59
24-37

Check wires for Mass Air Flow (MF) sensor
- Connect test box to control m...
Engine components,checking

Page 12 of 59
24-38

Throttle valve control module, checking
Recommended special tools and equ...
Engine components,checking

Page 13 of 59
24-39

Ground (GND) connections between engine,
transmission, and chassis must b...
Engine components,checking

Page 14 of 59
24-40

If the complete throttle valve control module is
current-less (e.g. conne...
Engine components,checking

Page 15 of 59
24-41

- Check specified value of throttle valve position
(absolute) at idle sto...
Engine components,checking

Page 16 of 59
24-42

If specified values are not obtained:
- Disconnect 8-pin connector at thr...
Engine components,checking

Page 17 of 59
24-43

- Replace Throttle Valve Control Module -J338Page 24-16 , item 8 .
- Eras...
Engine components,checking

Page 18 of 59
24-44

Checking voltage supply and wiring to
control module
- Connect multimeter...
Engine components,checking

Page 19 of 59
24-45

- Check wires between test box and 8-pin connector
to Engine Control Modu...
Engine components,checking

Page 20 of 59
24-46

Engine Coolant Temperature (ECT)
sensor, checking
Recommended special too...
Engine components,checking

Page 21 of 59
24-47

Function test
- Connect diagnostic tester

Page ST-7 .

- Switch ignition...
Engine components,checking

Page 22 of 59
24-48

If specified value is not obtained:
- Continue test according to the foll...
Engine components,checking

Page 23 of 59
24-49

Continuation of test if on display: approx. 46.0 C:
- Disconnect 2-pin co...
Engine components,checking

Page 24 of 59
24-50

If indication jumps to approx. 141.0 C:
- End diagnosis and switch igniti...
Engine components,checking

Page 25 of 59
24-51

Continuation of test if indication is approx.
141.0 C:
- Disconnect 2-pin...
Engine components,checking

Page 26 of 59
24-52

If indication remains at approx. 141.0 C:
- End diagnosis and switch igni...
Engine components,checking

Page 27 of 59
24-53

If no malfunctions are found in wires:
- Measure resistance at Engine Coo...
Engine components,checking

Page 28 of 59
24-54

If specified value is not obtained:
- Replace Engine Coolant Temperature ...
Engine components,checking

Page 29 of 59
24-55

Intake Air Temperature (IAT) Sensor,
checking
Recommended special tools a...
Engine components,checking

Page 30 of 59
24-56

- Under address word 33, select "Diagnostic
mode 1: Checking measured val...
Engine components,checking

Page 31 of 59
24-57

If specified value is obtained:
- Disconnect 2-pin connector from Intake ...
Engine components,checking

Page 32 of 59
24-58

If the intake air temperature does not drop:
- Replace Intake Air Tempera...
Engine components,checking

Page 33 of 59
24-59

- Erase DTC memory of Engine Control Module
(ECM) Page ST-25 , Diagnostic...
Engine components,checking

Page 34 of 59
24-60

If the indication remains at 141.0 C:
- End diagnosis and switch ignition...
Engine components,checking

Page 35 of 59
24-61

Range A displays resistance values for the
temperature range of 0 to 50 C...
Engine components,checking

Page 36 of 59
24-62

Engine speed (RPM) sensor, checking
Function
The Engine Speed (RPM) Senso...
Engine components,checking

Page 37 of 59
24-63

- Measure resistance of sensor between terminals 1
+ 2 of connector. Spec...
Engine components,checking

Page 38 of 59
24-64

- Check wires between test box and 3-pin connector
to Engine Control Modu...
Engine components,checking

Page 39 of 59
24-65

Fuel injectors, checking
Recommended special tools and equipment
V.A.G 15...
Engine components,checking

Page 40 of 59
24-66

Parking brake must be engaged or else
daylight driving lights will be swi...
Engine components,checking

Page 41 of 59
24-67

- Remove intake manifold upper part
12 , item 1 .

Page 24-

- Disconnect...
Engine components,checking

Page 42 of 59
24-68

Insert fuel injectors into fuel distributor
perpendicular and in the righ...
Engine components,checking

Page 43 of 59
24-69

- Connect diode test lamp to connector of tested fuel
injector terminal 1...
Engine components,checking

Page 44 of 59
24-70

If LED does not flicker:
- Connect test box to control module wiring
harn...
Engine components,checking

Page 45 of 59
24-71

Injection quantity and proper
seal of fuel injectors,
checking
Recommende...
Engine components,checking

Page 46 of 59
24-72

Test requirement
Fuel pressure must be OK, check Page
24-78 , fuel pressu...
Engine components,checking

Page 47 of 59
24-73

Checking proper seal
- Remove Fuel Pump (FP) Relay -J17- from relay
carri...
Engine components,checking

Page 48 of 59
24-74

If fuel loss is greater:
- Replace malfunctioning fuel injector
13 , item...
Engine components,checking

Page 49 of 59
24-75

Checking injection quantity
- Insert a fuel injector to be tested into a
...
Engine components,checking

Page 50 of 59
24-76

- Bridge terminals 4 + 6 on relay carrier using
appropriate adapter cable...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 ...
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010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 1997 (eng)

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010 volkswagen passat official factory repair manual (2.8 liter vr6 2 v generic scan tool fuel injection & ignition) 1996 1997 (eng)

  1. 1. 2.8 Liter VR6 2V Generic Scan Tool Fuel Injection & Ignition, Engine Code(s): AAA m.y. 1996-1997 20 - Fuel Supply Fuel supply system components, removing and installing Fuel tank with attachments and fuel filter, removing and installing Safety precautions when working on fuel supply Rules of cleanliness Fuel Pump (FP), removing and installing Fuel pump, checking EVAP canister system EVAP canister system, components, removing and installing (vehicles without Leak Detection Pump) EVAP canister system components, removing and installing (vehicles with Leak Detection Pump) Fuel tank ventilation, checking (vehicles without Leak Detection Pump) EVAP canister system for proper seal, checking (vehicles with Leak Detection Pump) Evaporative Emission (EVAP) canister purge regulator valve 1, checking Leak Detection Pump (LDP), checking Accelerator Pedal (AP) cable, adjusting Vehicles with manual transmission Vehicles with automatic transmission 24 - Multiport Fuel Injection (MFI) Motronic fuel injection and ignition system Component locations overview General Notes on Fuel Injection Fuel injection system components, removing and installing Fuel distributor with fuel injectors, disassembling and assembling Throttle valve control module, removing and installing Air filter, disassembling and assembling Safety precautions Rules of cleanliness Technical data Engine components,checking Oxygen sensor heater for oxygen sensor before Three Way Catalytic Converter (TWC), checking
  2. 2. Oxygen sensor heater for oxygen sensors behind Three Way Catalytic Converter (TWC), checking Mass Air Flow (MAF) sensor, checking Throttle valve control module, checking Engine Coolant Temperature (ECT) sensor, checking Intake Air Temperature (IAT) Sensor, checking Engine speed (RPM) sensor, checking Fuel injectors, checking Fuel pressure regulator and residual pressure, checking Intake system for leaks (false air), checking Function tests Oxygen sensor and oxygen sensor regulation before catalytic converter, checking Oxygen sensor and oxygen sensor regulation behind catalytic converter, 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 Exhaust system components, removing and installing Exhaust manifold, front exhaust pipe and catalytic converter with attachments Mufflers with mounts Three Way Catalytic Converter (TWC), checking Secondary Air Injection (AIR) system Function Secondary Air Injection (AIR) system components, removing and installing Secondary Air Injection (AIR) system, checking for proper seal Secondary Air Injection (AIR) valve, checking Secondary Air Injection (AIR) pump motor, checking Combination valve, checking
  3. 3. 28 - Ignition/Glow plug system Ignition, servicing General notes on ignition system Ignition components, removing and installing Safety precautions Test Data, Spark Plugs Camshaft Position (CMP) sensor, checking Knock sensors, checking Ignition coil, checking 38 - Automatic Transmission - Gears, Hydraulic controls Transmission control electrical components, removing and installing, checking Safety precautions Electrical/electronic components and component locations Multi-Function Transmission Range (TR) Switch, checking Transmission Vehicle Speed Sensor (VSS), checking Vehicle Speed Sensor (VSS), checking Transmission Fluid Temperature Sensor, checking Solenoid valves in valve body, checking Transmission Control Module (TCM) Function Transmission Control Module (TCM), replacing ST - Generic Scan Tool General information for On Board Diagnostic (OBD) Characteristics of On Board Diagnostic (OBD) On Board Diagnostic (OBD), technical data Diagnostic tester, connecting Test box, connecting for wiring test Diagnostic function, selecting Address word 33 - On-Board Diagnostic (OBD) Diagnostic mode 1: Check measured values Diagnostic mode 2: Check operating conditions Diagnostic mode 3: Check DTC Memory Diagnostic mode 4: Reset/erase diagnostic data Diagnostic mode 5: Check output of oxygen sensor signals Diagnostic mode 6: Check test results of components that are not continuously monitored Diagnostic mode 7: Check test results Diagnostic mode 8: Tank leak test
  4. 4. Readiness code Function Readiness code, reading Readiness code, generating DTC tables SAE P0xxx-DTCs SAE P1xxx-DTCs
  5. 5. Fuel supply system components, removing and installing Page 1 of 27 20-1 Fuel supply system components, removing and installing Note: Hose connections are secured with screw-type clamps, spring-type clamps or tensioning clamps. Fuel hoses at engine must only be secured with spring-type clamps. The use of clamping collars or screw clamps is not permitted. VAS 5024A spring-type clip pliers is recommended for installing spring clips. Fuel tank with attachments and fuel filter, removing and installing Page 20-2 . Observe safety precautions Observe rules for cleanliness EVAP canister system Page 20-8 . Page 20-10 . Page 20-28 . Adjusting accelerator pedal cable Page 20-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  6. 6. Fuel supply system components, removing and installing Page 2 of 27 20-2 Fuel tank with attachments and fuel filter, 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 (transfer of pump noise). 1 - Cap Replace seal if damaged 2 - Tensioning ring 3 - Rubber top 4 - Ground (GND) connection Check for secure fitting http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  7. 7. Fuel supply system components, removing and installing Page 3 of 27 20-3 5 - O-ring Replace if damaged 6 - Bleeder valve Checking Fig. 2 7 - Union nut, 60 Nm 8 - Expansion tank Version shown: Wagon For sedan, simpler expansion tank 9 - Vent line Filler ventilation Check for secure fitting 10 - Vent line Operating ventilation Only station wagon Check for secure fitting http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  8. 8. Fuel supply system components, removing and installing Page 4 of 27 20-4 11 - Return hose Blue Check for secure fitting From fuel return line at fuel distributor Page 24-12 , Item 5 12 - Union nut, 60 Nm Use wrench 3217 to remove and install 13 - Flange Note installation position at fuel tank Fig. 1 14 - Supply hose Check for secure fitting 15 - Seal Replace if damaged To 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.B4.FU08.20.1 12/6/2004
  9. 9. Fuel supply system components, removing and installing Page 5 of 27 20-5 16 - Return hose Check for secure fitting 17 - Sender for fuel gauge G18 - Fuel pump Removing and installing Page 2011 Checking Fuel Pump (FP) Page 20-15 19 - Tension strap Note varying lengths 20 - Bracket For tension straps 21 - 25 Nm 22 - Fuel tank http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  10. 10. Fuel supply system components, removing and installing Page 6 of 27 20-6 23 - Supply line Black Check for secure fitting To fuel supply line at fuel distributor Page 24-12 , Item 4 24 - Fuel filter Installation position: Arrow points in direction of flow 25 - Screw clip 26 - 10 Nm 27 - Vent line Check for secure fitting To EVAP canister Page 20-30 , item no. 7 28 - Gravity valve To remove, 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.B4.FU08.20.1 12/6/2004
  11. 11. Fuel supply system components, removing and installing Page 7 of 27 20-7 Fig. 1 Installation position of fuel pump flange Marking on flange must align with marking on fuel tank. Note: After installing Fuel Pump (FP) unit flange, check whether supply, return and vent lines are still clipped in at fuel tank. Fig. 2 Checking bleeder valve Lever in rest position: closed Lever pressed in direction of arrow: open http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  12. 12. Fuel supply system components, removing and installing Page 8 of 27 20-8 Safety precautions when working on fuel supply CAUTION! 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 followed. Watch for sufficient clearance to all moving or hot components. Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. Always observe the following when removing and installing the sender for fuel gauge or the Fuel Pump (FP) from partially filled fuel tanks. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  13. 13. Fuel supply system components, removing and installing Page 9 of 27 20-9 Before starting work, switch on exhaust extraction system and place an extraction hose close to the sensor opening in 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 m3/h can be used. Prevent gasoline from contacting skin! Wear fuel-resistant gloves! For safety reasons, fuse no. 18 must be removed from fuse holder before opening fuel supply system. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  14. 14. Fuel supply system components, removing and installing Page 10 of 27 20-10 Rules of cleanliness When working on the fuel supply or fuel injection system, the following "5 rules of cleanliness" should be carefully observed: Thoroughly clean all connections and the surrounding area before disconnecting. Place parts that have been removed on a clean surface and cover. Use lint-free cloths only! Carefully cover over opened components or seal, if repairs are not carried out immediately. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (in tool boxes etc.) When the system is open: Avoid working with compressed air if possible. Do not move vehicle unless absolutely necessary. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  15. 15. Fuel supply system components, removing and installing Page 11 of 27 20-11 Fuel Pump (FP), removing and installing Recommended special tools and equipment 3217 ring nut spanner V.A.G1332 torque wrench (40 to 200 Nm) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  16. 16. Fuel supply system components, removing and installing Page 12 of 27 20-12 Observe safety precautions Observe rules for cleanliness Page 20-8 . Page 20-10 . 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. In this case, determine anti-theft coding. - Switch ignition off and disconnect Battery Ground (GND) strap. - Remove luggage compartment floor cover. - Disconnect connector as well as supply and return line from flange. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  17. 17. Fuel supply system components, removing and installing Page 13 of 27 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! Wear protective goggles and protective gloves when working on the fuel system! - Seal off lines so that no dirt will get into fuel system. - Use 3217 ring nut spanner to remove union nut. - Pull flange and sealing ring from opening of fuel tank - Loosen fuel pump from bayonet connection by turning toward left and remove. Note: When replacing Fuel Pump (FP) unit, empty old Fuel Pump (FP) unit before disposing. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  18. 18. Fuel supply system components, removing and installing Page 14 of 27 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. Only coat seal with fuel when installing Fuel Pump (FP). Installed position of flange for Fuel Pump (FP) unit Page 20-7 , Fig. 1 . Make sure fuel lines are securely fastened. After installing Fuel Pump (FP) unit, check whether supply, return and vent lines are still clipped in at fuel tank. When the Fuel Pump (FP) unit is installed correctly, the floater of sender for fuel gauge faces in driving direction -A- as follows: Front Wheel Drive (FWD) vehicles Station wagon Sedan = 5 to 10 = 70 to 75 - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  19. 19. Fuel supply system components, removing and installing Page 15 of 27 20-15 Fuel pump, 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.G 1332 torque wrench (40 to 200 Nm) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  20. 20. Fuel supply system components, removing and installing Page 16 of 27 20-16 V.A.G 1348/3A remote control with V.A.G 1348/3-2 adapter cable V.A.G 1527B voltage tester V.A.G 1594 C connector test kit V.A.G 1715 multimeter VAS 5024A assembly tool for spring-type clamps Without illustration: Measuring container Wiring diagram http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  21. 21. Fuel supply system components, removing and installing Page 17 of 27 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. Parking brake must be engaged or else daylight driving lights will be switched on. For vehicles with automatic transmission, selector lever must be in -P-. Test sequence - Switch on ignition. Fuel Pump (FP) must briefly run audibly. - Switch ignition off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  22. 22. Fuel supply system components, removing and installing Page 18 of 27 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. Obtain radio code for radios with anti-theft coding before disconnecting battery. Do not use metallic tools to pry off relays from relay carrier. The terminals could conduct electricity. - Connect V.A.G 1348/3A remote control with V.A.G1348/3-2 remote control connection to terminal 4 and B+. - Operate remote control. If Fuel Pump (FP) runs: - Check activation of Fuel Pump (FP) Relay -J17according to wiring diagram: Electrical Wiring Diagrams, Troubleshooting & Component Locations http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  23. 23. Fuel supply system components, removing and installing Page 19 of 27 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 the outer terminals of the connector. - Operate remote control. LED must light up. LED does not light up: - Locate and repair open circuit using wiring diagram. Electrical Wiring Diagrams, Troubleshooting & Component Locations LED lights up (voltage supply OK): - Remove fuel pump Page 20-11 . - Check whether electrical wires between flange and Fuel Pump (FP) are connected. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  24. 24. Fuel supply system components, removing and installing Page 20 of 27 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-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . Checking fuel delivery Test requirements Voltage supply OK V.A.G 1348/3A remote control connected Test sequence - Remove fuel filler cap from fuel filler tube. - Disconnect fuel supply line from fuel rail. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  25. 25. Fuel supply system components, removing and installing Page 21 of 27 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! Wear protective goggles and protective gloves when working on the fuel system! - Connect pressure gauge (V.A.G 1318) with adapter ((V.A.G 1318/10) to fuel supply line -1-. - Connect V.A.G 1318/1 hose to V.A.G 1318/11 adapter of pressure gauge and hold in a measuring container. - Open shut-off valve of pressure gauge. Lever will point in direction of flow -A-. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  26. 26. Fuel supply system components, removing and installing Page 22 of 27 20-22 - Operate remote control. Slowly close shut-off valve until pressure gauge displays 3 bar positive pressure is indicated. Do not change position of shut-off valve any more. - Empty the measuring container. - Delivery rate of Fuel Pump (FP) is dependant on battery voltage. Therefore, connect multimeter to vehicle battery using adapter cables. - Operate remote control 30 seconds long. - Compare fuel quantity pumped with specified value. *) Minimum delivery rate cm3/30 s **) Voltage at fuel pump with engine off and pump running (approx. 2 volts less than battery voltage). Read-out example: During test, a voltage of 12.5 Volts is measured at battery. Since the voltage at the pump is approx. 2 Volts less than battery voltage, there is a minimum delivery rate of 550 cm3/30 s. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  27. 27. Fuel supply system components, removing and installing Page 23 of 27 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 rags around the connection area and release pressure by carefully loosening the connection! Wear protective goggles and protective gloves when working on the fuel system! - Connect pressure gauge (V.A.G 1318) to hose using adapter ((V.A.G 1318/10). - Repeat test of delivery quantity. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  28. 28. Fuel supply system components, removing and installing Page 24 of 27 20-24 If minimum delivery rate is now obtained: - 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 and check filter strainer for dirt. Only if no malfunctions have been found yet: - Fuel Pump (FP) faulty, replace Fuel Pump (FP) unit Page 20-11 , Fuel Pump (FP) unit, removing and installing. - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . Delivery rate has been obtained, but malfunctions are still suspected in the fuel supply (e.g. sporadic loss of fuel supply): - Reconnect all disconnected fuel lines. - Check current pick-up of Fuel Pump (FP) Page 20-25 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  29. 29. Fuel supply system components, removing and installing Page 25 of 27 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. Specified value: max. 8 amperes Note: If disturbance in fuel system is sporadic, test can also be performed during a road test, but a 2nd person is required. If current draw is exceeded: - Fuel Pump (FP) faulty, replace Fuel Pump (FP) unit Page 20-11 , Fuel Pump (FP) unit, removing and installing. - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  30. 30. Fuel supply system components, removing and installing Page 26 of 27 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. - Close pressure gauge shut-off valve (lever perpendicular to direction of flow). - Operate remote control in short intervals until a positive pressure of approx. 3.0 bar has built up. - If excess pressure is built up, reduce pressure by carefully opening shut-off valve. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  31. 31. Fuel supply system components, removing and installing Page 27 of 27 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. After 10 minutes, pressure must not fall below 2 bar within 10 minutes. If pressure drops further: - Check line connections for proper seal. If no malfunctions are found in wires: - Fuel Pump (FP) faulty, replace Fuel Pump (FP) unit Page 20-11 , Fuel Pump (FP) unit, removing and installing. - Re-connect all disconnected fuel lines. - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.1 12/6/2004
  32. 32. EVAP canister system Page 1 of 22 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 springtype clamps or screw-type clamps. Fuel hoses at engine must only be secured with spring-type clamps. The use of clamping collars or screw clamps is not permitted. Components marked with * are tested via On Board Diagnostic (OBD) Page ST-21 , Diagnostic mode 3: Check DTC memory. VAS5024A spring-type clip pliers is recommended for installing spring clips. Observe safety precautions Observe rules for cleanliness Page 20-8 . Page 20-10 . EVAP canister system components, removing and installing: Vehicles without Leak Detection Pump (LDP) Page 20-29 , Vehicles with Leak Detection Pump (LDP) Page 20-32 . Check fuel tank ventilation (vehicles without Leak Detection Pump) Page 20-36 . Check EVAP canister system for proper seal (vehicles with Leak Detection Pump) Page 2040 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  33. 33. EVAP canister system Page 2 of 22 20-29 EVAP canister system, components, removing and installing (vehicles without Leak Detection Pump) 1 - Vent line From gravity valve at fuel tank Page 206 , item 27 2 - Connector 2-pin 3 - Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-* Installation position: Arrow points in direction of flow Checking 43 Page 20- 4 - Retaining ring For Evaporative Emission (EVAP) canister purge regulator valve -N80- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  34. 34. EVAP canister system Page 3 of 22 20-30 5 - Bracket At lower section of air filter 6 - Upper part of intake manifold 7 - Vent line Check for secure fitting Note installed position Fig. 1 8 - From crankcase vent valve 9 - 10 Nm 10 - EVAP canister Component location: in wheelhousing, right front To remove, remove air filter housing with Mass Air Flow (MAF) Sensor -G70- Page 24-19 , disassembling and assembling air filter http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  35. 35. EVAP canister system Page 4 of 22 20-31 Fig. 1 Installed position of vent line on upper section of intake manifold Marking on vent line must align with marking on upper section of intake manifold (arrows). CAUTION! Vent line must not come into contact with other components and must be routed over the hose for crankcase ventilation. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  36. 36. EVAP canister system Page 5 of 22 20-32 EVAP canister system components, removing and installing (vehicles with Leak Detection Pump) 1 - EVAP canister Component location: in wheelhousing, right front To remove, remove air filter housing with Mass Air Flow (MAF) Sensor -G70- Page 24-19 , disassembling and assembling air filter 2 - Pressure regulation valve For fuel tank ventilation Vent line from gravity valve at fuel tank Page 20-6 , item 28 3 - Test connection http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  37. 37. EVAP canister system Page 6 of 22 20-33 4 - Retaining ring For Evaporative Emission (EVAP) canister purge regulator valve -N805 - Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-* Installation position: Arrow points in direction of flow Checking 43 Page 20- 6 - Connector 2-pin 7 - Upper part of intake manifold 8 - Vent line Check for secure fitting Note installed position Fig. 1 9 - From crankcase vent valve 10 - Air filter for diagnostic pump Clean if dirty http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  38. 38. EVAP canister system Page 7 of 22 20-34 11 - Leak Detection Pump (LDP) -V144-* 3-pin connector, black Checking 46 Page 20- 12 - Bleeder valve http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  39. 39. EVAP canister system Page 8 of 22 20-35 Fig. 1 Installed position of vent line on upper section of intake manifold Marking on vent line must align with marking on upper section of intake manifold (arrows). CAUTION! Vent line must not come into contact with other components and must be routed over the hose for crankcase ventilation. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  40. 40. EVAP canister system Page 9 of 22 20-36 Fuel tank ventilation, checking (vehicles without Leak Detection Pump) Recommended special tools and equipment V.A.G 1368 Vacuum tester V.A.G1390 hand vacuum pump Test requirement Ignition switched off http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  41. 41. EVAP canister system Page 10 of 22 20-37 Test sequence - Remove air filter Page 24-19 , disassembling and assembling air filter. - Disconnect ventilation hose -1- to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- (-6-) at upper section of intake manifold -2-. - For vehicles with crankcase vent valve, seal connection -7-. - Connect hand vacuum pump to hose -1-. - Disconnect ventilation hose -3- (for fuel tank) at EVAP canister -4- and connect to vacuum tester connection A-. - Connect vacuum tester -connection B- to connection on EVAP canister. - Set vacuum tester to position -B-. - Operate vacuum pump several times. There must be no vacuum building up. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  42. 42. EVAP canister system Page 11 of 22 20-38 If vacuum builds up: - Check breather connection -5- at EVAP canister -4- for soiling, clean if necessary. - Check Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- (-6-) for throughput, replace if necessary. If no vacuum builds up: - Unscrew 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. There must be no vacuum building up. If vacuum builds up: - Check gravity valve Page 20-6 , item 28 . - Check line -3- from fuel tank for throughput. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  43. 43. EVAP canister system Page 12 of 22 20-39 If no vacuum builds up: - Screw fuel filler cap on fuel filler tube. - Operate vacuum pump several times. There must be no vacuum building up. Note: At a low fuel level in fuel tank, hand vacuum pump must be operated at least 20 to 30 times. If vacuum builds up: - Replace fuel filler cap for fuel filler tube. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  44. 44. EVAP canister system Page 13 of 22 20-40 EVAP canister system for proper seal, checking (vehicles with Leak Detection Pump) Function test - Select measuring value "Test-ID 01: Tank leak test" and check whether the specified value is being reached Page ST-43 , Diagnostic mode 8: Tank leak test. - Check specified value of tank leak test at idle. Specified value: Test function active Note: During tank leak test, Engine Control Module (ECM) limits "test function active" to approx. 12 minutes. If the accelerator pedal is depressed during test, the test will be aborted. To repeat tank leak test, switch ignition off and start engine again and let run at idle for at least 15 minutes. - End diagnosis and switch ignition off. If a leak is detected: http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  45. 45. EVAP canister system Page 14 of 22 20-41 Checking proper seal If a small or large leak was recognized during the test of EVAP canister system, proceed as follows. - Remove Leak Detection Pump (LDP) -V144and seal connection piece to vent valve on EVAP canister Page 20-32 , EVAP canister system components (vehicles with Leak Detection Pump), removing and installing. - Repeat function test. If malfunction persists: - Check whether fuel filler cap of fuel filler tube is completely closed or whether the seal leaks; replace if necessary. - Check whether flange of Fuel Pump (FP) unit or sealing ring is leaking; replace if necessary Page 20-11 , Fuel Pump (FP) unit, removing and installing. - Repeat function test. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  46. 46. EVAP canister system Page 15 of 22 20-42 If malfunction persists: - Remove EVAP canister and check for cracks and leaks, replace if necessary Page 20-32 , EVAP canister system components, removing and installing (vehicles with Leak Detection Pump). - Check lines and hoses between EVAP canister and fuel filler tube or Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80for proper seal Page 20-32 , EVAP canister system components, removing and installing (vehicles with Leak Detection Pump). - Check hoses and hose clamps for secure seating. - Repeat function test. If malfunction is no longer present: - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  47. 47. EVAP canister system Page 16 of 22 20-43 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.G 1526 multimeter or V.A.G1715 multimeter V.A.G 1594 connector test kit Wiring diagram Test requirements The respective fuses of Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80must be OK: Electrical Wiring Diagrams, Troubleshooting & Component Locations Ground (GND) connections between engine, transmission, and chassis must be OK. Ignition switched off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  48. 48. EVAP canister system Page 17 of 22 20-44 Test sequence - Disconnect 2-pin connector from Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-: Vehicles without Leak Detection Pump (LDP) Page 20-29 , item 2 , Vehicles with Leak Detection Pump (LDP) Page 20-33 , item 6 . - Measure resistance between terminals of solenoid valve. Specified value: 22.0 to 30.0 If specified value is not obtained: - Replace Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-: Vehicles without Leak Detection Pump (LDP) Page 20-29 , item 3 , Vehicles with Leak Detection Pump (LDP) Page 20-33 , item 5 . - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  49. 49. EVAP canister system Page 18 of 22 20-45 If specified value is obtained: - Check wires according to wiring diagram Page 20-45 . Checking wiring - Connect test box to control module wiring harness Page ST-10 , connect test box for wiring test. - Check wire connection between test box and 2-pin connector for open circuit according to wiring diagram: Electrical Wiring Diagrams, Troubleshooting & Component Locations - Check the wire for short circuit to B+ and to Ground (GND). Specified value: - Check wire between 2-pin connector and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram: Electrical Wiring Diagrams, Troubleshooting & Component Locations - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) J220- Page 24-101 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  50. 50. EVAP canister system Page 19 of 22 20-46 Leak Detection Pump (LDP), checking Recommended special tools and equipment V.A.G 1526 multimeter or V.A.G1715 multimeter V.A.G 1594 connector test kit Wiring diagram Requirements The respective fuses of Leak Detection Pump (LDP) -V144- must be OK: Electrical Wiring Diagrams, Troubleshooting & Component Locations Ground (GND) connections between engine and chassis must be OK. Ignition switched off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  51. 51. EVAP canister system Page 20 of 22 20-47 Work sequence - Remove right rear wheelhousing liner. - Disconnect 3-pin connector of Leak Detection Pump (LDP) -V144-. Checking resistances - Measure resistance between terminals 1 + 3 of diagnostic pump. Specified value: 640 to 720 - Measure resistance between terminals 2 + 3 of diagnostic pump. Specified value: 12.0 to 20.0 If specified values are not obtained: - Replace Leak Detection Pump (LDP) -V144Page 20-34 , item 11 - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . If specified values are obtained: - Check wires according to wiring diagram 20-48 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 Page 12/6/2004
  52. 52. EVAP canister system Page 21 of 22 20-48 Checking wiring - Connect test box to control module wiring harness Page ST-10 , connect test box for wiring test. - Check wires between test box and 3-pin connector for open circuits according to wiring diagram. Terminal 1 + socket 46 Terminal 2 + socket 35 Wire resistance: max. 1.5 - Check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: - Check wire between 3-pin connector terminal 3 and relay carrier for open circuit according to wiring diagram: Electrical Wiring Diagrams, Troubleshooting & Component Locations http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  53. 53. EVAP canister system Page 22 of 22 20-49 - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220- Page 24-101 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.2 12/6/2004
  54. 54. Accelerator Pedal (AP) cable, adjusting Page 1 of 4 20-50 Accelerator Pedal (AP) cable, adjusting Vehicles with manual transmission Requirement Ignition switched off Work procedure - Remove spark plugs with ignition wires Page 28-3 , Ignition components, removing and installing - Remove ignition wire guides -1- and -2-. - Remove cover over upper section of intake manifold -3-. - Press accelerator pedal to Wide Open Throttle (WOT) position. - Adjust accelerator pedal cable via swapping of positioning clip (arrow) at support bracket so that Wide Open Throttle (WOT) position is reached on throttle valve lever. - Release accelerator pedal. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.3 12/6/2004
  55. 55. Accelerator Pedal (AP) cable, adjusting Page 2 of 4 20-51 Vehicles with automatic transmission Recommended special tools and equipment Spacer piece 15 mm V.A.G 1526 multimeter or V.A.G 1715 multimeter V.A.G 1594 connector test kit Requirement Ignition switched off Work procedure - Remove spark plugs with ignition wires Page 28-3 , Ignition components, removing and installing - Remove ignition wire guides -1- and -2-. - Remove cover over upper section of intake manifold -3-. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.3 12/6/2004
  56. 56. Accelerator Pedal (AP) cable, adjusting Page 3 of 4 20-52 - Spacer piece -1-, a = 15 mm, clamp between accelerator pedal -2and stop -3- and hold accelerator pedal firmly in this position. - Open throttle valve completely by pulling on accelerator pedal cable sleeve and secure in this position using positioning clip (arrow). - Release accelerator pedal. - Disconnect 2-pin harness connector from Kick Down Switch -F8- in engine compartment at front (on cross panel). http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.3 12/6/2004
  57. 57. Accelerator Pedal (AP) cable, adjusting Page 4 of 4 20-53 - Connect hand multimeter with adapter cables to Kick Down Switch -F8-. - Measure resistance at switch. Specified value: (no continuity) - Move accelerator pedal slowly in direction of Wide Open Throttle (WOT). Shortly after kickdown point, resistance must drop to 0 (continuity). For this, accelerator pedal must be slightly before stop. - Release accelerator pedal. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.20.3 12/6/2004
  58. 58. Motronic fuel injection and ignition system Page 1 of 26 24-1 Motronic fuel injection and ignition system Component locations overview Note: Components marked with * are tested via On Board Diagnostic (OBD) Page ST-21 , Diagnostic mode 3: Check DTC memory. Component location of Secondary Air Injection (AIR) Pump Relay -J299-* Page 26-16 , Fig. 1. 1 - Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-* Vehicles without Leak Detection Pump (LDP) Page 20-29 , item 3 Vehicles with Leak Detection Pump (LDP) Page 20-33 , item 5 2 - Mass Air Flow (MAF) Sensor -G70-* http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  59. 59. Motronic fuel injection and ignition system Page 2 of 26 24-2 3 - Intake hose With Positive Crankcase Ventilation (PCV) Heating Element -N794 - Knock Sensor (KS) 1 G61-* Page 28-5 , item 12 5 - Engine Control Module (ECM)* (control module for Motronic Engine Control Module (ECM) -J220-) 6 - Throttle Valve Control Module -J338-* 7 - Ground (GND) connection 8 - Ignition Coil -N152Page 28-4 , item 6 9 - A/C Cut-Out Thermal Switch -F163- and Third Speed Coolant Fan Control (FC) Thermal Switch -F165Brown, 4-pin Only for vehicles with A/C system http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  60. 60. Motronic fuel injection and ignition system Page 3 of 26 24-3 10 - Engine Coolant Temperature (ECT) Sensor -G62-* Blue, 2-pin For Engine Control Module (ECM) 11 - After-Run Coolant Fan Control (FC) Thermal Switch -F87- with Engine Coolant Temperature (ECT) Sensor -G2Yellow, 4-pin 12 - Intake Air Temperature (IAT) Sensor -G72-* 13 - Fuel pressure regulator 14 - Engine Speed (RPM) Sensor -G28-* 15 - Knock Sensor (KS) 2 G66-* Page 28-4 , item 10 16 - Secondary Air Injection (AIR) pump motor V101-* Page 26-13 , item 1 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  61. 61. Motronic fuel injection and ignition system Page 4 of 26 24-4 17 - Fuel injector (-N30- to N33-, -N83-, -N84-)* Checking 65 Page 24- 18 - EVAP canister Vehicles without Leak Detection Pump (LDP) Page 20-30 , item 10 Vehicles with Leak Detection Pump (LDP) Page 20-32 , item 1 19 - Air filter http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  62. 62. Motronic fuel injection and ignition system Page 5 of 26 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. Vacuum hoses and connections should also be checked (false air). For the electric components to work properly, a voltage of at least 11.5 V is required. Do not use any silicone sealant. Traces of silicone components which are sucked into the engine are not burned there, and they damage the oxygen sensors. The battery must only be disconnected and connected with the ignition switched off, since the Engine Control Module (ECM) can otherwise be damaged. Fuel hoses at engine must only be secured with spring-type clamps. The use of clamping collars or screw clamps is not permitted. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  63. 63. Motronic fuel injection and ignition system Page 6 of 26 24-6 VAS 5024A spring-type clip pliers is recommended for installing spring-type clips. Components marked with * are tested via On Board Diagnostic (OBD) Page ST-21 , Diagnostic mode 3: Check DTC memory. It is possible that the control module will recognize a malfunction and store a DTC during some tests. Therefore the following work steps must be performed in the mentioned sequence after ending all tests and repairs. - - Check DTC memory Page ST-21 , Diagnostic mode 3: Check DTC Memory, - - Erase DTC memory Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data - - For completion, generate readiness code Page ST-50 . Safety precautions Rules of cleanliness Technical data Page 24-22 . Page 24-25 . Page 24-26 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  64. 64. Motronic fuel injection and ignition system Page 7 of 26 24-7 Fuel injection system components, removing and installing 1 - Connector 68-pin Switch ignition off before disconnecting or connecting connector Disengage to pull off 2 - 10 Nm 3 - Engine Control Module (ECM)* (control module for Motronic Engine Control Module (ECM) -J220-) Component location: In plenum chamber, right side 68-pin connector Checking voltage supply Page 24-97 Always replace Page 24-101 4 - Securing plate For Motronic Engine Control Module (ECM) -J220- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  65. 65. Motronic fuel injection and ignition system Page 8 of 26 24-8 5 - 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, do NOT allow locking compound to get into slots on sensor body Voltage supply of oxygen sensor heater via Fuel Pump (FP) Relay -J17Check oxygen sensor heater for Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) Page 24-30 Check Oxygen Sensor (O2S) and oxygen sensor control behind Three Way Catalytic Converter (TWC) Page 24-91 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  66. 66. Motronic fuel injection and ignition system Page 9 of 26 24-9 6 - Heated Oxygen Sensor (HO2S) 1 -G39-*, 50 Nm Component location: in front catalytic converter Only grease threads with G 052 112 A3 locking compound, do NOT allow locking compound to get into slots on sensor body Voltage supply of oxygen sensor heater via Fuel Pump (FP) Relay -J17Check oxygen sensor heater for Oxygen Sensor (O2S) before Three Way Catalytic Converter (TWC) Page 24-27 Check Oxygen Sensor (O2S) and oxygen sensor control before Three Way Catalytic Converter (TWC) Page 24-86 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  67. 67. Motronic fuel injection and ignition system Page 10 of 26 24-10 7 - Engine Coolant Temperature (ECT) Sensor -G62-* Blue, 2-pin For Engine Control Module (ECM) If necessary, release pressure in cooling system before removing Checking 46 Page 24- 8 - Retaining clip Check for secure fitting 9 - O-ring Replace if damaged 10 - Connector 2-pin 11 - Engine Speed (RPM) Sensor -G28-* Component location: Cylinder block, intake side Checking 62 Page 24- 12 - 4-pin harness connector Black For Heated Oxygen Sensor (HO2S) -G39and oxygen sensor heater http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  68. 68. Motronic fuel injection and ignition system Page 11 of 26 24-11 13 - Bracket For harness connector for oxygen sensors and Knock Sensor (KS) 1 14 - 20 Nm 15 - 4-pin harness connector Brown For Heated Oxygen Sensor (HO2S) 2 G108- and oxygen sensor heater http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  69. 69. Motronic fuel injection and ignition system Page 12 of 26 24-12 Fuel distributor with fuel injectors, disassembling and assembling 1 - Upper part of intake manifold 2 - Wiring channel 3 - Locking bolt For test connection 4 - Supply hose White marking Secure with spring type clamps Check for secure fitting From fuel filter 20-6 , item 24 Page 5 - Return hose Blue marking Secure with spring type clamps Check for secure fitting To flange of Fuel Pump (FP) Page 20-5 , item 18 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  70. 70. Motronic fuel injection and ignition system Page 13 of 26 24-13 6 - Fuel distributor 7 - 10 Nm 8 - 25 Nm 9 - Lower part of intake manifold 10 - Gasket Always replace 11 - O-ring Always replace Lightly lubricate Orings with clean engine oil before installing 12 - Fuel injector (-N30- to N33-, -N83-, -N84-)* Checking 65 Page 24- 13 - Retaining clip Check for secure fitting 14 - Fuel pressure regulator Checking 78 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 Page 24- 12/6/2004
  71. 71. Motronic fuel injection and ignition system Page 14 of 26 24-14 15 - Connector 2-pin For fuel injector (-N30to -N33-, -N83-, -N84-) 16 - Intake Air Temperature (IAT) Sensor -G72-*, 10 Nm 2-pin connector Checking 55 Page 24- 17 - Vacuum hose Check for secure fitting http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  72. 72. Motronic fuel injection and ignition system Page 15 of 26 24-15 Throttle valve control module, removing and installing 1 - Upper part of intake manifold First tighten at lower section of intake manifold, then tighten both rear supports (item 13 and item 4 ) 2 - Wiring channel 3 - 10 Nm 4 - Right rear support Between upper part of intake manifold and cylinder head 5 - 25 Nm 6 - Vacuum hose Check for secure fitting From Secondary Air Injection (AIR) Solenoid Valve -N112Page 26-14 , item 7 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  73. 73. Motronic fuel injection and ignition system Page 16 of 26 24-16 7 - Ventilation hose Check for secure fitting Note installed position Fig. 1 From Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80Page 24-19 , item 5 8 - Throttle valve control module -J338-* Heated by coolant Components of Throttle Valve Control Module -J338-:Throttle Position (TP) Actuator -V60-, Throttle Position (TP) Sensor -G127-, Throttle Position (TP) Sensor -G69- and Closed Throttle Position (CTP) Switch -F60Checking 38 Page 24- Adjusting accelerator pedal cable Page 20-50 9 - Connector 8-pin For Throttle Valve Control Module -J338- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  74. 74. Motronic fuel injection and ignition system Page 17 of 26 24-17 10 - Gasket Always replace 11 - Pivot For accelerator pedal cable Adjusting accelerator pedal cable Page 20-50 12 - Ground (GND) wire Check for secure fitting 13 - Rear left support Between upper part of intake manifold and cylinder head With Ground (GND) connection, engine http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  75. 75. Motronic fuel injection and ignition system Page 18 of 26 24-18 Fig. 1 Installed position of vent line on upper section of intake manifold Marking on vent line must align with marking on upper section of intake manifold (arrows). CAUTION! Vent line must not come into contact with other components and must be routed over the hose for crankcase ventilation. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  76. 76. Motronic fuel injection and ignition system Page 19 of 26 24-19 Air filter, disassembling and assembling 1 - Upper part of air filter 2 - Filter element 3 - Lower part of air filter 4 - O-ring Replace if damaged 5 - Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-* 2-pin connector Installation position: Arrow points in direction of flow Checking 43 Page 20- 6 - Retaining ring For Evaporative Emission (EVAP) canister purge regulator valve -N807 - Connector 4 pin For Mass Air Flow (MAF) Sensor -G70- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  77. 77. Motronic fuel injection and ignition system Page 20 of 26 24-20 8 - Mass Air Flow (MAF) Sensor -G70-* Checking 33 Page 24- 9 - Intake hose Check for secure fitting Note installed position 10 - Positive Crankcase Ventilation (PCV) Heating Element -N79Arrow on heating element points in direction of stream Resistance at ambient temperature (approx. 25 C) Specified value: 7 to 12 11 - Connector 2-pin For Positive Crankcase Ventilation (PCV) Heating Element -N79Check voltage supply for PCV heating element between terminals 1 and 2 with engine running Specified value: at least 11.5 V http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  78. 78. Motronic fuel injection and ignition system Page 21 of 26 24-21 12 - Crankcase vent valve 13 - To upper part of intake manifold Page 24-16 , item 7 14 - Rubber washer 15 - Retaining ring Replace if damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  79. 79. Motronic fuel injection and ignition system Page 22 of 26 24-22 Safety precautions CAUTION! 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 followed. Shift selector lever into position -P- and engage parking brake before working with the engine running. WARNING Watch for sufficient clearance to all moving or hot components. Fuel system is under pressure! Before loosening hose connections or separating points, place rags around the connection point. Then release pressure by carefully opening the fuel supply system. The fuel or fuel lines in fuel system can become very hot (danger of scalding)! Wear protective goggles and protective gloves when working on the fuel system! http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  80. 80. Motronic fuel injection and ignition system Page 23 of 26 24-23 If special testing equipment is required during road test, note the following: Test equipment must always be secured to the rear seat and operated from there by a second person. If test and measuring equipment is operated from the passenger seat, the person seated there could be injured in the event of an accident involving deployment of the passenger-side airbag. To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following: Do not touch or disconnect ignition wires when engine is running or turning at starting RPM. Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition is switched off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  81. 81. Motronic fuel injection and ignition system Page 24 of 26 24-24 If engine is to be cranked at starting RPM without starting: - Disconnect 5-pin connector (arrow) from Ignition Coil -N152-. - Remove fuse 18 from fuse holder. Note: By removing fuse 18, voltage supply to the fuel pump is interrupted. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  82. 82. Motronic fuel injection and ignition system Page 25 of 26 24-25 Rules of cleanliness When working on the fuel supply or fuel injection system, the following "5 rules of cleanliness" should be carefully observed: Thoroughly clean all connections and the surrounding area before disconnecting. Place parts that have been removed on a clean surface and cover. Use lint-free cloths only! Carefully cover over opened components or seal, if repairs are not carried out immediately. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (in tool boxes etc.) When the system is open: Avoid working with compressed air if possible. Do not move vehicle unless absolutely necessary. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  83. 83. Motronic fuel injection and ignition system Page 26 of 26 24-26 Technical data Engine Code AAA Idle speed1) 650 to 750 RPM Engine Control Module (ECM)2) System identification Terminals at Engine Control Module (ECM) Replacement part number Engine speed (RPM) limitation 1) Replacing Engine Control Module (ECM) 68 See parts catalog at approx. 6600 RPM Not adjustable. 2) Motronic M5.9 Page 24-101 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.1 12/6/2004
  84. 84. Engine components,checking Page 1 of 59 24-27 Engine components,checking Oxygen sensor heater for oxygen sensor before Three Way Catalytic Converter (TWC), checking Recommended special tools and equipment V.A.G 1526 multimeter or V.A.G 1715 multimeter V.A.G 1594 connector test kit Wiring diagram Test requirements The respective fuses of Heated Oxygen Sensor (HO2S) -G39- must be OK: Electrical Wiring Diagrams, Troubleshooting & Component Locations Fuel Pump (FP) Relay -J17- must be OK, check: Electrical Wiring Diagrams, Troubleshooting & Component Locations Ground (GND) connections between engine, transmission, and chassis must be OK. Ignition switched off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  85. 85. Engine components,checking Page 2 of 59 24-28 Test sequence - Disconnect 4-pin harness connector (black) to Heated Oxygen Sensor (HO2S) -G39- (item no. 1). - Check resistance for sensor heater at connector to oxygen sensor terminal 1 + 2. Specified value: 1.0 to 24.2 temperature) (at room If specified value is not obtained: - Replace Heated Oxygen Sensor (HO2S) 1 Bank 1 -G39- before catalytic converter Page 24-9 , item 6 . - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  86. 86. Engine components,checking Page 3 of 59 24-29 If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater Page 24-29 . Checking Ground (GND) activation of oxygen sensor heating - Connect test box to control module wiring harness Page ST-10 , connect test box for wiring test. - Check wires between test box and 4-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 2 + socket 12 Wire resistance: max. 1.5 - Check wires for short circuit to B+ and to Ground (GND). Specified value: - Check wire between 4-pin connector terminal 1 and Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) J220- Page 24-101 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  87. 87. Engine components,checking Page 4 of 59 24-30 Oxygen sensor heater for oxygen sensors behind Three Way Catalytic Converter (TWC), checking Recommended special tools and equipment V.A.G 1526 multimeter or V.A.G1715 multimeter V.A.G 1594 connector test kit Wiring diagram Test requirements The respective fuses of Heated Oxygen Sensor (HO2S) -G108- must be OK: Electrical Wiring Diagrams, Troubleshooting & Component Locations Fuel Pump (FP) Relay -J17- must be OK, check: Electrical Wiring Diagrams, Troubleshooting & Component Locations Ground (GND) connections between engine, transmission, and chassis must be OK. Ignition switched off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  88. 88. Engine components,checking Page 5 of 59 24-31 Test sequence - Disconnect 4-pin harness connector (brown) to Heated Oxygen Sensor (HO2S) 2 -G108- (-2-). - Check resistance for sensor heater at connector to oxygen sensor terminal 1 + 2. Specified value: 1.0 to 24.2 temperature) (at room If specified value is not obtained: - Replace Oxygen Sensor (O2S) 2 Bank 1 Behind Three Way Catalytic Converter (TWC) -G108Page 24-8 , item 5 . - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  89. 89. Engine components,checking Page 6 of 59 24-32 If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater Page 24-32 . Checking Ground (GND) activation of oxygen sensor heating - Connect test box to control module wiring harness Page ST-10 , connect test box for wiring test. - Check wires between test box and 4-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 2 + socket 66 Wire resistance: max. 1.5 - Check wires for short circuit to B+ and to Ground (GND). Specified value: - Check wire between 4-pin connector terminal 1 and Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) J220- Page 24-101 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  90. 90. Engine components,checking Page 7 of 59 24-33 Mass Air Flow (MAF) sensor, checking Recommended special tools and equipment V.A.G 1526 multimeter or V.A.G1715 multimeter V.A.G 1594 connector test kit Wiring diagram Test requirements The respective fuse of Mass Air Flow (MAF) Sensor -G70- must be OK: Electrical Wiring Diagrams, Troubleshooting & Component Locations Fuel Pump (FP) Relay -J17- must be OK, check: Electrical Wiring Diagrams, Troubleshooting & Component Locations Battery voltage must be at least 11.5 Volts. All electrical consumers such as, lights and rear window defroster must be switched off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  91. 91. Engine components,checking Page 8 of 59 24-34 Parking brake must be engaged or else daylight driving lights will be switched on. For vehicles with automatic transmission, selector lever must be in -P-. If vehicle is equipped with an A/C system, it must be switched off. Ground (GND) connections between engine, transmission, and chassis must be OK. Coolant temperature must be at least 80 C Page ST-14 , Diagnostic mode 1: Check measured values; PID 5, Coolant temperature. Function test - Connect diagnostic tester Page ST-7 . - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 16: Air flow quantity at Mass Air Flow (MAF) sensor". http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  92. 92. Engine components,checking Page 9 of 59 24-35 - Check specified value of air flow quantity at Mass Air Flow (MAF) Sensor at idle: PID Diagnostic text Specified value: 16: Air flow quantity at Mass Air Flow (MAF) sensor 3.00 to 5.00 g/sec Engine running at idle - End diagnosis and switch ignition off. If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF) sensor: - Check voltage supply of Mass Air Flow (MAF) sensor Page 24-36 . If specified value is not obtained: - Check signal and Ground (GND) wires of Mass Air Flow (MAF) sensor Page 24-37 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  93. 93. Engine components,checking Page 10 of 59 24-36 Voltage supply for Mass Air Flow (MAF) sensor, checking - Disconnect 4-pin connector -1- from Mass Air Flow (MAF) Sensor -G70- (-2-). - Connect multimeter to terminals 1 + 3 of connector for voltage measurement. - Start engine, and let run at idle. Specified value: 11.0 to 15.0 V - Switch ignition off. If there is no voltage: - Check wire between 4-pin connector terminal 3 and Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 - Check wire to terminal 1 of 4-pin connector for open circuit according to wiring diagram: Electrical Wiring Diagrams, Troubleshooting & Component Locations If voltage supply and wires are OK: - Check wires of Mass Air Flow (MAF) sensor Page 24-37 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  94. 94. Engine components,checking Page 11 of 59 24-37 Check wires for Mass Air Flow (MF) sensor - Connect test box to control module wiring harness Page ST-10 , connect test box for wiring test. - Check wires between test box and 4-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 2 + socket 16 Terminal 4 + socket 17 Wire resistance: max. 1.5 - Check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: If no DTCs are found in wires: - Replace Mass Air Flow (MAF) Sensor -G70Page 24-20 , item 8 . - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  95. 95. Engine components,checking Page 12 of 59 24-38 Throttle valve control module, checking Recommended special tools and equipment V.A.G 1526 multimeter or V.A.G1715 multimeter V.A.G 1594 connector test kit Wiring diagram Test requirements The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: Electrical Wiring Diagrams, Troubleshooting & Component Locations Battery voltage must be at least 11.5 Volts. All electrical consumers such as, lights and rear window defroster must be switched off. If vehicle is equipped with an A/C system, it must be switched off. Parking brake must be engaged or else daylight driving lights will be switched on. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  96. 96. Engine components,checking Page 13 of 59 24-39 Ground (GND) connections between engine, transmission, and chassis must be OK. For vehicles with automatic transmission, selector lever must be in -P-. Throttle valve must not be damaged or dirty. Throttle valve must be in Closed Throttle Position (CTP). Adjustment of accelerator pedal cable must be OK Page 20-50 , adjusting accelerator pedal cable. Coolant temperature must be at least 80 C Page ST-14 , Diagnostic mode 1: Check measured values; PID 5, Coolant temperature. Function Components of throttle valve control -J338-: Closed Throttle Position (CTP) Switch -F60Throttle Position (TP) sensor -G69Throttle Position (TP) Sensor -G127Throttle Position (TP) Actuator -V60- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  97. 97. Engine components,checking Page 14 of 59 24-40 If the complete throttle valve control module is current-less (e.g. connector disconnected) the throttle valve moves into a particular, specified mechanical position, which signals an increased idle speed with an engine at operating temperature. If only the Throttle Position (TP) Actuator -V60- is current-less, the throttle valve also moves into the specified mechanical position (emergency running gap), however, since Closed Throttle Position (CTP) Switch -F60- can still be recognized, an "almost normal idle RPM" is reached via the respective ignition angle retardation. If the Engine Control Module (ECM) detects a malfunction at Throttle Position (TP) Sensor G69-, Throttle Position (TP) Actuator -V60- is switched current-less by the Engine Control Module (ECM) and the throttle valve moves into the specified mechanical position (emergency running gap) again. Function test - Connect diagnostic tester Page ST-7 . - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 17: Throttle valve position (absolute)." http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  98. 98. Engine components,checking Page 15 of 59 24-41 - Check specified value of throttle valve position (absolute) at idle stop: PID 17: Diagnostic text Specified value: Throttle valve position (absolute) Idle stop 0.0 to 7.0% - Slowly depress accelerator pedal up to Wide Open Throttle (WOT) stop while observing the percentage display. The percentage display must increase uniformly. - Check specified value of throttle valve position (absolute) at Wide Open Throttle (WOT) stop: PID Diagnostic text 17: Throttle valve position (absolute) Wide Open Throttle (WOT) stop Specified value: 80.0 to 100.0% - End diagnosis and switch ignition off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  99. 99. Engine components,checking Page 16 of 59 24-42 If specified values are not obtained: - Disconnect 8-pin connector at throttle valve control module (arrow). - Check resistance of throttle valve control module Page 24-42 . Checking resistance - Measure resistance of Throttle Position (TP) Actuator -V60- between the terminals 1 + 2. Specified value: 3.0 to 200.0 temperature) (at room - Measure resistance of Closed Throttle Position (CTP) Switch -F60- between terminals 3 + 7 in idle position. Specified value: Max. 10.0 temperature) (at room - Slowly open throttle valve up to Wide Open Throttle (WOT) Specified value: . If specified values are not obtained: http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  100. 100. Engine components,checking Page 17 of 59 24-43 - Replace Throttle Valve Control Module -J338Page 24-16 , item 8 . - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . If specified values are obtained: - Check voltage supply of throttle valve control module and wiring to control module Page 2444 . If voltage supply and wires are OK: - Replace Motronic Engine Control Module (ECM) -J220- Page 24-101 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  101. 101. Engine components,checking Page 18 of 59 24-44 Checking voltage supply and wiring to control module - Connect multimeter to terminals 3 + 7 of connector for voltage measurement. - Switch ignition on. Specified value: at least 9.0 V - Switch ignition off. - Connect multimeter to terminals 4 + 7 of connector for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. If specified values are not obtained: - Connect test box to control module wiring harness Page ST-10 , connect test box for wiring test. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  102. 102. Engine components,checking Page 19 of 59 24-45 - Check wires between test box and 8-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 1 + socket 27 Terminal 2 + socket 53 Terminal 3 + socket 10 Terminal 4 + socket 41 Terminal 5 + socket 40 Terminal 7 + socket 33 Terminal 8 + socket 62 Wire resistance: max. 1.5 - Check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: If no malfunctions are found in wires: - Check voltage supply of Engine Control Module (ECM) Page 24-97 . - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  103. 103. Engine components,checking Page 20 of 59 24-46 Engine Coolant Temperature (ECT) sensor, checking Recommended special tools and equipment V.A.G 1526 multimeter or V.A.G1715 multimeter V.A.G 1594 connector test kit Wiring diagram Test requirements The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: Electrical Wiring Diagrams, Troubleshooting & Component Locations Parking brake must be engaged or else daylight driving lights will be switched on. For vehicles with automatic transmission, selector lever must be in -P-. Engine must be cold. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  104. 104. Engine components,checking Page 21 of 59 24-47 Function test - Connect diagnostic tester Page ST-7 . - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 05: Coolant temperature". - Check specified value of coolant temperature: PID 05: Diagnostic text Coolant temperature Specified value: approx. coolant temperature http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  105. 105. Engine components,checking Page 22 of 59 24-48 If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause Continue testing approx. 46.0 C Open circuit or short circuit to B+ Page 2449 approx. 141.0 C Short circuit to Ground (GND) Page 2451 1) If a temperature is indicated which differs greatly from ambient temperature of sensor, check sensor wires for contact resistance. If specified value is obtained: - Start engine and let run at idle. The temperature must climb uniformly Note: The temperature increases in increments of 1.5 C . If the engine shows problems in certain temperature ranges and if the temperature does not climb uniformly, the temperature signal is intermittent and the sensor should be replaced. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  106. 106. Engine components,checking Page 23 of 59 24-49 Continuation of test if on display: approx. 46.0 C: - Disconnect 2-pin connector from Engine Coolant Temperature (ECT) Sensor (arrow). - Bridge terminals 1 + 2 of connector using the respective adapter cables and observe the indication on display. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  107. 107. Engine components,checking Page 24 of 59 24-50 If indication jumps to approx. 141.0 C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- Page 24-10 , item 7 . WARNING! Cooling system is under pressure. Danger of scalding when opening! - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . If indication remains at approx. -46.0 C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram Page 24-52 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  108. 108. Engine components,checking Page 25 of 59 24-51 Continuation of test if indication is approx. 141.0 C: - Disconnect 2-pin connector from Engine Coolant Temperature (ECT) Sensor (arrow). If indication jumps to approx. -46.0 C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- Page 24-10 , item 7 . WARNING! Cooling system is under pressure. Danger of scalding when opening! - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  109. 109. Engine components,checking Page 26 of 59 24-52 If indication remains at approx. 141.0 C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram Page 24-52 . Checking wiring - Connect test box to control module wiring harness Page ST-10 , connect test box for wiring test. - Check wires between test box and 2-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 1 + socket 14 Terminal 2 + socket 33 Wire resistance: max. 1.5 - Check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  110. 110. Engine components,checking Page 27 of 59 24-53 If no malfunctions are found in wires: - Measure resistance at Engine Coolant Temperature (ECT) Sensor -G62-. Range A displays resistance values for the temperature range of 0 to 50 C, range B displays resistance values for the temperature range of 50 to 100 C. Read-out examples: 30 C is in range A and corresponds to a resistance of 1.5 to 2.0 k 80 C is in range B and corresponds to a resistance of 275 to 375 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  111. 111. Engine components,checking Page 28 of 59 24-54 If specified value is not obtained: - Replace Engine Coolant Temperature (ECT) Sensor -G62- Page 24-10 , item 7 . WARNING! Cooling system is under pressure. Danger of scalding when opening! - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220- Page 24-101 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  112. 112. Engine components,checking Page 29 of 59 24-55 Intake Air Temperature (IAT) Sensor, checking Recommended special tools and equipment V.A.G 1526 multimeter or V.A.G1715 multimeter V.A.G 1594 connector test kit Wiring diagram Chilling spray (commercially available) Test requirements The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: Electrical Wiring Diagrams, Troubleshooting & Component Locations Parking brake must be engaged or else daylight driving lights will be switched on. For vehicles with automatic transmission, selector lever must be in -P-. Function test - Connect diagnostic tester Page ST-7 . - Switch ignition on. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  113. 113. Engine components,checking Page 30 of 59 24-56 - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 15: Intake air temperature". - Check specified value of intake air temperature: PID Diagnostic text Specified value: 15: Intake Air Temperature (intake manifold temperature) approx. ambient temperature If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause Continue testing approx. 46.5 C Open circuit or short circuit to B+ Page 2458 approx. 141.0 C Short circuit to Ground (GND) Page 2459 1) If a temperature is indicated which is below the ambient temperature of sensor, first check sensor wires for contact resistance. Note that while the vehicle is standing still the sensor might warm up due to radiant heat. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  114. 114. Engine components,checking Page 31 of 59 24-57 If specified value is obtained: - Disconnect 2-pin connector from Intake Air Temperature (IAT) Sensor (arrow). - Unscrew Intake Air Temperature (IAT) Sensor G72- and reconnect to connector. - Seal threaded bore for sensor. - Remember the intake air temperature value. - Spray sensor with commercially available chilling spray while observing the temperature value. Temperature must decrease. - End diagnosis and switch ignition off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  115. 115. Engine components,checking Page 32 of 59 24-58 If the intake air temperature does not drop: - Replace Intake Air Temperature (IAT) Sensor G72- Page 24-14 , item 16 . - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . Continuation of test if display shows -46.5 C: - Disconnect 2-pin connector from Intake Air Temperature (IAT) Sensor (arrow). - Bridge terminals 1 + 2 of connector using the respective adapter cables while observing the indication on display. If indication jumps to approx. 141.0 C: - End diagnosis and switch ignition off. - Replace Intake Air Temperature (IAT) Sensor G72- Page 24-14 , item 16 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  116. 116. Engine components,checking Page 33 of 59 24-59 - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . If indication remains at approx. -46.5 C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram Page 24-60 . Continuation of test if display shows 141.0 C: - Disconnect 2-pin connector from Intake Air Temperature (IAT) Sensor (arrow). If indication jumps to approx. -46.5 C: - End diagnosis and switch ignition off. - Replace Intake Air Temperature (IAT) Sensor G72- Page 24-14 , item 16 . - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  117. 117. Engine components,checking Page 34 of 59 24-60 If the indication remains at 141.0 C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram Page 24-60 . Checking wiring - Connect test box to control module wiring harness Page ST-10 , connect test box for wiring test. - Check wires between test box and 2-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 1 + socket 36 Terminal 2 + socket 33 Wire resistance: max. 1.5 - Check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: If no malfunctions are found in wire: - Check resistance of Intake Air Temperature (IAT) Sensor -G72- terminals 1 + 2. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  118. 118. Engine components,checking Page 35 of 59 24-61 Range A displays resistance values for the temperature range of 0 to 50 C, range B displays resistance values for the temperature range of 50 to 100 C. Read-out examples: 30 C is in range A and corresponds to a resistance of 1.5 to 2.0 k 80 C is in range B and corresponds to a resistance of 275 to 375 If specified value is not obtained: - Replace Intake Air Temperature (IAT) Sensor G72- Page 24-14 , item 16 . - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) J220- Page 24-101 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  119. 119. Engine components,checking Page 36 of 59 24-62 Engine speed (RPM) sensor, checking Function The Engine Speed (RPM) Sensor -G28- detects engine speed and reference marks. Without an engine speed signal, the engine will not start. If the engine speed signal fails while the engine is running, the engine will stop immediately. Recommended special tools and equipment V.A.G 1526 multimeter or V.A.G1715 multimeter V.A.G 1594 connector test kit Wiring diagram Test sequence - Disconnect white 3-pin harness connector to engine speed (RPM) sensor (arrow). http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  120. 120. Engine components,checking Page 37 of 59 24-63 - Measure resistance of sensor between terminals 1 + 2 of connector. Specified value: 480 to 1000 - Check sensor for short circuit between terminals 1 +3 and 2 + 3. Specified value: If specified values are not obtained: - Replace Engine Speed (RPM) Sensor -G28Page 24-10 , item 11 . - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . If no DTC is found on sensor: - Connect test box to control module wiring harness Page ST-10 , connect test box for wiring test. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  121. 121. Engine components,checking Page 38 of 59 24-64 - Check wires between test box and 3-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 1 + socket 67 Terminal 2 + socket 68 Terminal 3 + socket 56 Wire resistance: max. 1.5 - Check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: If no malfunctions are found in wires: - Remove sensor and check sensor wheel for secure fit, damage, and run-out. Note: There is a larger-sized gap on the sensor wheel. This gap is the reference mark and does not mean that the sensor wheel is damaged. If nothing seems to be wrong with the sensor wheel: - Replace Motronic Engine Control Module (ECM) J220- Page 24-101 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  122. 122. Engine components,checking Page 39 of 59 24-65 Fuel injectors, checking Recommended special tools and equipment V.A.G 1526 multimeter or V.A.G1715 multimeter V.A.G 1527 voltage test lamp V.A.G 1594 connector test kit Wiring diagram Test requirements The respective fuses of fuel injectors (-N30- to N33-, -N83-, -N84-) must be OK: Electrical Wiring Diagrams, Troubleshooting & Component Locations Fuel Pump (FP) Relay -J17- must be OK, check: Electrical Wiring Diagrams, Troubleshooting & Component Locations Battery voltage must be at least 11.5 Volts. All electrical consumers such as, lights and rear window defroster must be switched off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  123. 123. Engine components,checking Page 40 of 59 24-66 Parking brake must be engaged or else daylight driving lights will be switched on. For vehicles with automatic transmission, selector lever must be in -P-. If vehicle is equipped with an A/C system, it must be switched off. Ground (GND) connections between engine, transmission, and chassis must be OK. Engine Speed (RPM) Sensor -G28- OK, check Page 24-62 . Ignition switched off. Test sequence Observe safety precautions Observe rules for cleanliness Page 24-22 . Page 24-25 . - Remove spark plugs with ignition wires Page 28-3 , Ignition components, removing and installing - Remove ignition wire guides -1- and -2-. - Remove cover over upper section of intake manifold -3-. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  124. 124. Engine components,checking Page 41 of 59 24-67 - Remove intake manifold upper part 12 , item 1 . Page 24- - Disconnect fuel injector connectors. Resistance values of fuel injectors, checking - Test resistance of fuel injectors between terminals. Specified value: 15.0 to 21.5 Note: Resistance value is valid at approx. 20 C. At higher temperatures, resistance value increases. If specified value is not obtained: - Replace malfunctioning fuel injector 13 , item 12 . Page 24- Note the following when installing the fuel injectors: Replace O-rings on all fuel injectors and wet them slightly with clean motor oil. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  125. 125. Engine components,checking Page 42 of 59 24-68 Insert fuel injectors into fuel distributor perpendicular and in the right position, and secure them with retaining clips. Position fuel distributor on lower part of intake manifold using secured fuel injectors and apply uniform pressure to press it in. The connectors must audibly engage on valves when attached. - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . Checking voltage supply - Disconnect 5-pin connector (arrow) from Ignition Coil -N152-. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  126. 126. Engine components,checking Page 43 of 59 24-69 - Connect diode test lamp to connector of tested fuel injector terminal 1 and Ground (GND). - Operate starter and test voltage supply for fuel injector. LED must light up. - Switch ignition off. If LED does not light up: - Check wire between 2-pin connector terminal 2 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 Checking activation - Connect diode test lamp to the connector terminals of the fuel injector to be checked. - Operate starter and test activation of fuel injector. LED should flicker. - Switch ignition off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  127. 127. Engine components,checking Page 44 of 59 24-70 If LED does not flicker: - Connect test box to control module wiring harness Page ST-10 , connect test box for wiring test. - Check wires between test box and 2-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max. 1.5 Component Connector Test box Cylinder 1 Fuel Injector N30- Terminal 2 Socket 24 Cylinder 2 Fuel Injector N31- Terminal 2 Socket 25 Cylinder 3 Fuel Injector N32- Terminal 2 Socket 26 Cylinder 4 Fuel Injector N33- Terminal 2 Socket 2 Cylinder 5 Fuel Injector N83- Terminal 2 Socket 3 Cylinder 6 Fuel Injector N84- Terminal 2 Socket 4 - Check wires for short circuit to B+ and to Ground (GND). Specified value: If there is no malfunction in wire connection: - Replace Motronic Engine Control Module (ECM) J220- Page 24-101 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  128. 128. Engine components,checking Page 45 of 59 24-71 Injection quantity and proper seal of fuel injectors, checking Recommended special tools and equipment V.A.G 1348/3A remote control with V.A.G 1348/3-2 adapter cable V.A.G 1602 tester for quantity of injected fuel Without illustration: V.A.G 1594A connector test kit http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  129. 129. Engine components,checking Page 46 of 59 24-72 Test requirement Fuel pressure must be OK, check Page 24-78 , fuel pressure regulator and retaining pressure, checking. Test sequence - Remove spark plugs with ignition wires Page 28-3 , Ignition components, removing and installing - Remove ignition wire guides -1- and -2-. - Remove cover over upper section of intake manifold -3-. - Remove intake manifold upper part 12 , item 1 . Page 24- Note: Seal the intake channels in lower part of intake manifold using a clean rag. - Disconnect fuel injector connectors. - Then remove fuel rail completely, fuel hoses remain connected Page 24-13 , item 6 . - Lift fuel distributor with fuel injectors off lower part of intake manifold and support it. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  130. 130. Engine components,checking Page 47 of 59 24-73 Checking proper seal - 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. Obtain radio code for radios with anti-theft coding before disconnecting battery. Do not use metallic tools to pry off relays from relay carrier. The terminals could conduct electricity. - Bridge terminals 4 + 6 on relay carrier using appropriate adapter cables. Fuel Pump (FP) must run. - Check proper seal of fuel injectors (visual inspection). With Fuel Pump (FP) running, only 1 to 2 drops per minute should escape from each valve. - Disconnect the connection between relay carrier terminals. - Insert Fuel Pump (FP) Relay -J17- into relay carrier. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  131. 131. Engine components,checking Page 48 of 59 24-74 If fuel loss is greater: - Replace malfunctioning fuel injector 13 , item 12 . Page 24- Note the following when installing fuel injectors: Replace O-rings on all fuel injectors and wet them slightly with clean motor oil. Insert fuel injectors into fuel distributor perpendicular and in the right position, and secure them with retaining clips. Position fuel distributor on lower part of intake manifold using secured fuel injectors and apply uniform pressure to press it in. The connectors must audibly engage on valves when attached. - Erase DTC memory of Engine Control Module (ECM) Page ST-25 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  132. 132. Engine components,checking Page 49 of 59 24-75 Checking injection quantity - Insert a fuel injector to be tested into a measuring tube of V.A.G 1602 tester for fuel injection quantity. - Using respective adapter cables, connect one terminal of fuel injector to be checked to engine Ground (GND). - Use adapter cable to connect second terminal of fuel injector to V.A.G 1348/3 remote control with V.A.G 1348/3-2 adapter cable. - Connect alligator clip to B+. - 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. Obtain radio code for radios with anti-theft coding before disconnecting battery. Do not use metallic tools to pry off relays from relay carrier. The terminals could conduct electricity. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004
  133. 133. Engine components,checking Page 50 of 59 24-76 - Bridge terminals 4 + 6 on relay carrier using appropriate adapter cables. Fuel Pump (FP) must run. - Operate remote control for 30 seconds. - Repeat test on other fuel injectors. Use new graduated measuring glasses for this. Note: Check spray pattern when checking injection quantity. Spray pattern must be the same for all injectors - After all fuel injectors have been activated, place graduated measuring glasses on a level surface and compare quantity of injected fuel. Specified value: 90 to 130 ml per injector - Disconnect connection between relay carrier terminals. - Insert Fuel Pump (FP) Relay -J17- into relay carrier. If measured value of one or more fuel injectors is below or above the indicated specified value: - Replace malfunctioning fuel injector 13 , item 12 . Page 24- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.FU08.24.2 12/6/2004

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