Ebook english 007-volkswagen_passat_official_factory_repair_manual_tool_fuel_injection_ignition (eng)

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Ebook english 007-volkswagen_passat_official_factory_repair_manual_tool_fuel_injection_ignition (eng)

  1. 1. 2.0 Liter 4-Cyl. 2V Generic Scan Tool Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1996-1997 20 - Fuel Supply Fuel supply system components, removing and installing Fuel filter and fuel tank with attaching parts, removing and installing Safety precautions when working on fuel supply system Rules of cleanliness Fuel pump, removing and installing Fuel Pump (FP), checking EVAP canister system EVAP canister system components, removing and installing Fuel tank ventilation, checking Evaporative Emission (EVAP) canister purge regulator valve 1, 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 Overview of component locations General Notes on Fuel Injection Fuel injector parts, servicing Intake manifold, upper part, disassembling and assembling Intake manifold, lower part, disassembling and assembling Air filter, disassembling and assembling Safety precautions Rules of cleanliness Technical data Components of engine, checking Oxygen sensor heater for oxygen sensor before Three Way Catalytic Converter (TWC), checking Oxygen sensor heater for oxygen sensorbehind 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
  2. 2. Function tests Oxygen sensor and oxygen sensor regulation before catalytic converter, checking Oxygen sensor and oxygen sensor regulation behind catalytic converter, checking Intake air pre-heating, checking Engine Control Module (ECM) Function Voltage supply for Engine Control Module (ECM), checking Engine Control Module (ECM), replacing Additional signals, Checking Speed signal, checking 26 - Exhaust system, Emission controls 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 28 - Ignition/Glow plug system Ignition, servicing General notes on ignition system Ignition components, removing and installing Safety precautions Test Data, Spark Plugs Ignition distributor, removing and installing Camshaft Position (CMP) sensor, checking Knock sensors, checking Ignition coil, checking End stage for ignition coil, checking 37 - Automatic Transmission - Controls, Housing Selector lever mechanism, servicing Safety precautions Selector lever mechanism, (vehicles without ignition key removal lock), disassembling and assembling
  3. 3. Selector lever mechanism, (vehicles with ignition key removal lock), disassembling and assembling Selector lever, (vehicles with ignition key removal lock), disassembling and assembling Locking cable (vehicles with ignition key removal lock), removing and installing Locking cable (vehicles with ignition key removal lock), adjusting Selector lever cable, checking and adjusting Ignition key removal lock (vehicles with ignition key removal lock), checking 38 - Automatic Transmission - Gears, Hydraulic controls Electrical components of transmission control, 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 mode, 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 Readiness code Function Read readiness code Readiness code, generating
  4. 4. Diagnostic Trouble Code (DTC) tables: SAE P0xxx-DTCs SAE P1xxx-DTCs SAE P2xxx-DTCs SAE P3xxx-DTCs
  5. 5. Fuel supply system components, removing and installing Page 1 of 29 20-1 Fuel supply system components, removing and installing Note: Hose connections are secured with click-type clamps, spring-type clamps or open clips with insert. Fuel hoses at engine must only be secured with spring-type clamps. The use of click-type clamps or open clips with insert is not permitted. VAS5024A spring clip installation tool is recommended for installing spring-type 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 20-37 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  6. 6. Fuel supply system components, removing and installing Page 2 of 29 20-2 Fuel filter and fuel tank with attaching parts, removing and installing Note: Make sure the supply or return lines do not come into contact with the fuel tank after all work on the fuel pump or the fuel gauge (transfer of pump noise). 1 - Cap Replace seal if damaged 2 - Circlip 3 - Rubber top 4 - Ground (GND) connection Check for secure seating http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  7. 7. Fuel supply system components, removing and installing Page 3 of 29 20-3 5 - O-ring Replace if damaged 6 - Vent 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 seating 10 - Vent line Operating ventilation Only station wagon Check for secure seating http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  8. 8. Fuel supply system components, removing and installing Page 4 of 29 20-4 11 - Return hose Blue Check for secure seating From fuel return line at fuel distributor Page 24-14 , Item 35 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 seating 15 - Seal Replace if damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  9. 9. Fuel supply system components, removing and installing Page 5 of 29 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... 6/12/2004
  10. 10. Fuel supply system components, removing and installing Page 6 of 29 20-5 16 - Return hose Check for secure seating 17 - Sender for fuel gauge -G18 - Fuel pump (FP) -GRemoving and installing Page 20-11 Checking Fuel Pump (FP) Page 2015 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... 6/12/2004
  11. 11. Fuel supply system components, removing and installing Page 7 of 29 20-6 23 - Supply line Black Check for secure seating To fuel supply line at fuel distributor Page 24-14 , Item 34 24 - Fuel filter Installation position: (Arrow) points in direction of flow 25 - Screw clip 26 - 10 Nm 27 - Vent line Check for secure seating To EVAP canister Page 20-29 , item no. 6 28 - Gravity valve To remove, http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  12. 12. Fuel supply system components, removing and installing Page 8 of 29 unclip valve upward and lift out. Checking valve for throughput Valve vertical: open, Valve tilted 45 : closed http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  13. 13. Fuel supply system components, removing and installing Page 9 of 29 20-7 Fig. 1 Installation position of Fuel Pump (FP) flange Mark on flange must align with mark on fuel tank Note: After installing Fuel Pump (FP) unit flange, check whether supply, return and ventilation lines are still clipped in at fuel tank. Fig. 2 Checking vent 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... 6/12/2004
  14. 14. Fuel supply system components, removing and installing Page 10 of 29 20-8 Safety precautions when working on fuel supply system WARNING! Observe the following for all installations, especially in engine compartment due to lack of room: Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is 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 full or partially filled fuel tanks. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  15. 15. Fuel supply system components, removing and installing Page 11 of 29 20-9 Before starting work, switch on exhaust extraction system and place an extraction hose close to the installation opening of fuel tank to extract escaping fuel fumes. If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m 3/h can be used. Prevent fuel 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... 6/12/2004
  16. 16. Fuel supply system components, removing and installing Page 12 of 29 20-10 Rules of cleanliness When working on the fuel supply or fuel injection systems, the following "5 rules of cleanliness" should be carefully observed: Thoroughly clean all connections and the surrounding area before disconnecting. Place parts that have been removed on a clean surface and cover them. Use lint-free cloths only! Carefully cover over opened components or seal, if repairs are not performed 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. Do not move vehicle unless absolutely necessary. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  17. 17. Fuel supply system components, removing and installing Page 13 of 29 20-11 Fuel pump, removing and installing Recommended special tools and equipment 3217 Ring nut spanner V.A.G1332 Torque wrench (40 to 200 Nm) Observe safety precautions 8. Observe rules for cleanliness 20-10 . Page 20Page http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  18. 18. Fuel supply system components, removing and installing Page 14 of 29 20-12 Requirements Parking brake must be engaged or else daylight driving lights will be switched on. Ignition switched off. Fuel tank must be drained. Removing - First determine whether a coded radio is installed. In this case, determine the 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... 6/12/2004
  19. 19. Fuel supply system components, removing and installing Page 15 of 29 20-13 WARNING! The fuel or fuel lines in fuel system can become very hot (danger of scalding)! In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection! 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... 6/12/2004
  20. 20. Fuel supply system components, removing and installing Page 16 of 29 20-14 Installing Installation of the fuel pump is the reverse order of removal. Note: When inserting Fuel Pump (FP) unit into fuel tank, be sure not to bend sender for fuel gauge. Coat seal with fuel when installing Fuel Pump (FP). 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 ventilation 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-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  21. 21. Fuel supply system components, removing and installing Page 17 of 29 20-15 Fuel Pump (FP), checking Recommended special tools and equipment 3217 Ring nut spanner V.A.G 1318 Pressure gauge V.A.G 1318/1 Hose V.A.G 1318/10 Adapter V.A.G 1318/11 Adapter V.A.G1332 Torque wrench (40 to 200 Nm) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  22. 22. Fuel supply system components, removing and installing Page 18 of 29 20-16 V.A.G1348/3A Remote control with V.A.G1348/32 adapter cable V.A.G1527B Voltage tester V.A.G 1594 C Connector test kit V.A.G1715 Multimeter VAS5024A Assembly tool for spring-type clamps Not illustrated: Measuring container Wiring diagram http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  23. 23. Fuel supply system components, removing and installing Page 19 of 29 20-17 Test requirements Fuse no. 18 for Fuel Pump (FP) must be OK. Battery voltage must be at least 11.5 volts. Ground (GND) connections between engine, transmission, and chassis must be OK. All electrical consumers such as lights and rear window defroster must be switched off. 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... 6/12/2004
  24. 24. Fuel supply system components, removing and installing Page 20 of 29 20-18 If Fuel Pump (FP) does not start up: - Remove Fuel Pump (FP) Relay -J17from 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 -J17- according to wiring diagram: Electrical Wiring Diagrams, Troubleshooting & Component Locations http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  25. 25. Fuel supply system components, removing and installing Page 21 of 29 20-19 If Fuel Pump (FP) does not run: - Remove luggage compartment floor cover. - Disconnect connector from flange on fuel tank. - Connect diode test lamp to outer terminals of connector. - 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... 6/12/2004
  26. 26. Fuel supply system components, removing and installing Page 22 of 29 20-20 If there are no open circuits: - Fuel Pump (FP) faulty, replace Fuel Pump (FP) Page 20-11 , Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . Checking fuel delivery Test requirements Voltage supply OK V.A.G1348/3A 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... 6/12/2004
  27. 27. Fuel supply system components, removing and installing Page 23 of 29 20-21 WARNING! The fuel or fuel lines in fuel system can become very hot (danger of scalding)! In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection! 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 - 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... 6/12/2004
  28. 28. Fuel supply system components, removing and installing Page 24 of 29 20-22 - Operate remote control. Slowly close shut-off valve until on pressure gauge 3 bar positive pressure is indicated. Do not change position of shut-off valve any more. - Empty measuring container. - Delivery rate of Fuel Pump (FP) is dependent on battery voltage. Therefore, connect multimeter to vehicle battery using adapter cables. - Operate remote control for 3 seconds long. - Compare fuel quantity pumped with specified value. *) Minimum delivery rate cm 3/30 s **) Voltage at Fuel Pump (FP) 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 530 cm 3/30 s. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  29. 29. Fuel supply system components, removing and installing Page 25 of 29 20-23 If minimum delivery rate is not obtained: - Check fuel lines for possible restrictions (kinks) or clogging. - Disconnect supply hose -1- from fuel filter input. WARNING! The fuel or fuel lines in fuel system can become very hot (danger of scalding)! In addition, the fuel system is under pressure!Before opening the system, place 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... 6/12/2004
  30. 30. Fuel supply system components, removing and installing Page 26 of 29 20-24 If minimum delivery rate is obtained now: - Replace fuel filter Page 20-6 item 24 , removing and installing fuel tank with attachments and fuel filter If minimum delivery rate is still not obtained: - Remove fuel delivery unit Page 20-11 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-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . 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... 6/12/2004
  31. 31. Fuel supply system components, removing and installing Page 27 of 29 20-25 Current pick-up of Fuel Pump (FP), checking - Connect multimeter with current probe to red/yellow wire of wiring harness. - Start engine and let run at idle. - Measure Fuel Pump (FP) current draw. Specified value: max. 8 amperes Note: If malfunction in fuel system is sporadic, test can also be performed during a road test, but a second 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 ST26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code ST-52 . Page http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  32. 32. Fuel supply system components, removing and installing Page 28 of 29 20-26 Fuel Pump (FP) check-valve, checking Test requirements Remote control connected Pressure gauge is still connected. Test sequence Note: This test also checks the connections of the fuel supply line from Fuel Pump (FP) unit to connection point of pressure gauge for proper seal. - Close pressure gauge shut-off valve (lever perpendicular to direction of flow, -position B-). - 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 shutoff valve. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  33. 33. Fuel supply system components, removing and installing Page 29 of 29 20-27 WARNING! Danger of spray when opening shut-off valve. Hold container in front of open connection on pressure gauge. - Observe pressure drop on pressure gauge. Pressure must not fall below 2 bar. If pressure drops further: - Check line connections for proper seal. 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-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  34. 34. EVAP canister system Page 1 of 10 20-28 EVAP canister system Note: Hose connections are secured with screw-type clamps, spring-type clamps or tensioning clamps. Always replace tensioning clamps with 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-22 , Diagnostic mode 3: Check DTC memory. VAS5024A spring clip installation tool is recommended for installing spring-type clips. Observe safety precautions Observe rules for cleanliness Page 20-8 . Page 20-10 . Removing and installing components of the EVAP canister system Page 20-29 . Fuel tank ventilation, checking Page 20-31 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  35. 35. EVAP canister system Page 2 of 10 20-29 EVAP canister system components, removing and installing 1 - Connector Black, 2pin 2 - Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80* Black Installation position: (Arrow) points in direction of flow Checking Page 20-34 3 - Bracket At lower section of air filter 4 - Retaining ring 5 - Throttle valve connection 6 - Ventilation line http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  36. 36. EVAP canister system Page 3 of 10 Check for secure seating From gravity valve at fuel tank Page 20-6 , item 27 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  37. 37. EVAP canister system Page 4 of 10 20-30 7 - EVAP canister Component location: in wheelhousing, right front To remove, press securing tab in direction of (arrow) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  38. 38. EVAP canister system Page 5 of 10 20-31 Fuel tank ventilation, checking Recommended special tools and equipment V.A.G 1368 Vacuum tester V.A.G1390 Hand vacuum pump Test required Ignition switched off http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  39. 39. EVAP canister system Page 6 of 10 20-32 Test sequence - Remove air filter 1. Page 24-7 , item - Disconnect bleeder hose to EVAP canister -4- at Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- (-6-). - Connect hand vacuum pump to hose. - Disconnect bleeder hose -3- (from fuel tank) at EVAP canister -4- and connect to vacuum tester ((V.A.G 1368) connection -A-. - Connect vacuum tester ((V.A.G 1368) connection -B- to connection on EVAP canister. - Set vacuum tester to position -B-. - Operate vacuum pump several times. There must be no vacuumbuilding up. 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. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  40. 40. EVAP canister system Page 7 of 10 20-33 If no vacuum builds up: - Remove fuel filler cap from fuel filler tube. - Connect hand vacuum pump to vacuum tester connection -B-. - Set vacuum tester to position -A/B-. - Operate Vacuum pump several times. There must be no vacuumbuilding up. If vacuum builds up: - Check gravity valve item 28 . Page 20-6 , - Check line -3- from fuel tank for throughput. If no vacuum builds up: - Screw fuel filler cap on fuel filler tube. - Operate vacuum pump several times. There must be no vacuumbuilding 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... 6/12/2004
  41. 41. EVAP canister system Page 8 of 10 20-34 Evaporative Emission (EVAP) canister purge regulator valve 1, checking Solenoid valve is closed when no voltage is present. Recommended special tools and equipment V.A.G1526 Multimeter or V.A.G1715 multimeter V.A.G1594 Connector test kit Wiring diagram http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  42. 42. EVAP canister system Page 9 of 10 20-35 Test requirements The respective fuses of Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- must be OK: Electrical Wiring Diagrams, Troubleshooting & Component Locations Ground (GND) connections between engine, transmission and chassis must be OK. Ignition switched off. Test sequence - Disconnect 2-pin connector from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80- Page 20-29 , item 1 . - 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- Page 20-29 , item 2 . - Erase DTC memory of Engine Control Module (ECM) Page ST26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code ST-52 . Page http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  43. 43. EVAP canister system Page 10 of 10 20-36 If specified value is obtained: - Check wires according to wiring diagram Page 20-36 . Checking wiring - Connect test box to control module wiring harness Page ST-11 , connect test box for wiring test. - Check wire between test box socket 31 + 2-pin connector terminal 2 for open circuit according to wiring diagram. Wire resistance: max. 1.5 - Check the wire for short circuit to B+ and Ground (GND). Specified value: - Check wire between 2-pin connector terminal 1 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 - Erase DTC memory from Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220Page 24-105 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  44. 44. Accelerator Pedal (AP) cable, adjusting Page 1 of 3 20-37 Accelerator Pedal (AP) cable, adjusting Vehicles with manual transmission Requirement Ignition switched off Procedure - Press accelerator pedal to Wide Open Throttle (WOT) position. - Adjust accelerator pedal cable via swapping of positioning clip at support bracket so that Wide Open Throttle (WOT) position is just reached on cable pulley of throttle valve control module. - Release accelerator pedal. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  45. 45. Accelerator Pedal (AP) cable, adjusting Page 2 of 3 20-38 Vehicles with automatic transmission Recommended special tools and equipment Spacer piece 15 mm V.A.G1526 Multimeter or V.A.G1715 multimeter V.A.G1594 Connector test kit Requirement Ignition switched off Procedure Test sequence - Spacer piece -1-, a = 15 mm, clamp between accelerator pedal -2- and stop -3- and hold accelerator pedal firmly in this position. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  46. 46. Accelerator Pedal (AP) cable, adjusting Page 3 of 3 20-39 - Adjust accelerator pedal cable via swapping of positioning clip at support bracket so that Wide Open Throttle (WOT) position is reached on throttle valve lever. - Release accelerator pedal. - Connect hand multimeter with adapter cables to Kick Down Switch F8-. - 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 sink to 0 (continuity). For this, accelerator pedal must be slightly before stop. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  47. 47. Motronic fuel injection and ignition system Page 1 of 37 24-1 Motronic fuel injection and ignition system Overview of component locations Note: Components marked with * are tested via On Board Diagnostic (OBD) Page ST-22 , Diagnostic mode 3: Check DTC memory. 1 - Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80* Page 20-29 , item 2 2 - Mass Air Flow (MAF) Sensor G70-* 3 - Throttle valve control http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  48. 48. Motronic fuel injection and ignition system Page 2 of 37 module J338-* 4 - Engine Control Module (ECM)* (control module for Motronic Engine Control Module (ECM) J220-) Component location: in plenum chamber 68-pin connector Checking voltage supply Page 24101 Replace Page 24-105 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  49. 49. Motronic fuel injection and ignition system Page 3 of 37 24-2 5 - 4-pin harness connector Brown For Heated Oxygen Sensor (HO2S) 2 -G108and oxygen sensor heater 6 - 4-pin harness connector Black For Heated Oxygen Sensor (HO2S) G39- and oxygen sensor heater 7 - Intake Air Temperature (IAT) Sensor -G72-* 8 - Ignition Coil N152Page 28-4 , item 7 9 - Speedometer Vehicle Speed http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  50. 50. Motronic fuel injection and ignition system Page 4 of 37 Sensor (VSS) -G22Checking Page 24-106 , checking speed signal http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  51. 51. Motronic fuel injection and ignition system Page 5 of 37 24-3 10 Engine - Coolant Temperature (ECT) Sensor G62-* Black For Engine Control Module (ECM) With Engine Coolant Temperature (ECT) Sensor (G2) If necessary, release pressure in cooling system before removing 11 - Central harness connector 12 - 3-pin harness connector For Knock Sensor (KS) 1 G61Blue 13 - 3-pin harness connector http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  52. 52. Motronic fuel injection and ignition system Page 6 of 37 For Engine Speed (RPM) Sensor G2814 - Engine Speed (RPM) Sensor G28-* 15 - Secondary Air Injection (AIR) pump motor V101-* Page 26-15 , item 12 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  53. 53. Motronic fuel injection and ignition system Page 7 of 37 24-4 16 - Distributor with Camshaft Position (CMP) Sensor G40-* Page 28-5 , item 17 17 - Fuel injectors (N30through N33-)* 18 - Knock Sensor (KS) 1 G61-* Page 28-4 , item 10 19 - Ground (GND) connection 20 - Fuel pressure regulator 21 Temperature - regulator For intake air preheating 22 - EVAP canister Page 20-30 , item 7 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  54. 54. Motronic fuel injection and ignition system Page 8 of 37 24-5 General Notes on Fuel Injection Servicing ignition Page 28-1 . Note: Engine Control Module (ECM) is equipped with On Board Diagnostic (OBD). Always check DTC memory first, before performing repairs or troubleshooting. 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 sensor. The battery must only be disconnected and connected with the ignition switched off, since the Engine Control Module (ECM) can be damaged. Fuel hoses at engine must 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... 6/12/2004
  55. 55. Motronic fuel injection and ignition system Page 9 of 37 24-6 VAS5024A spring clip installation tool is recommended for installing spring-type clips. Components marked with * are tested via On Board Diagnostic (OBD) Page ST-22 , Diagnostic mode 3: Check DTC memory. It is possible that the control module will recognize a malfunction and store a DTC during some tests. The following work procedures must be performed in the mentioned sequence after ending all tests and repairs. Page - - Check DTC memory ST-22 , Diagnostic mode 3: Check DTC Memory, - - Erase DTC memory Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data - - For completion, generate readiness code Page ST-52 . Safety precautions Rules of cleanliness Technical data Page 24-21 . Page 24-23 . Page 24-24 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  56. 56. Motronic fuel injection and ignition system Page 10 of 37 24-7 Fuel injector parts, servicing 1 - Air filter Disassembling and assembling Page 24-19 2 - Connector 4 pin For Mass Air Flow (MAF) Sensor G703 - Ventilation line Check for secure seating From Evaporative Emission (EVAP) Canister Purge Regulator Valve Page 2029 , item 2 4 - Intake hose Check for secure seating Note installed position http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  57. 57. Motronic fuel injection and ignition system Page 11 of 37 Secure with spring clamps 5 - Pressure regulator valve for crankshaft housing ventilation http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  58. 58. Motronic fuel injection and ignition system Page 12 of 37 24-8 6 - Connector 8-pin For Throttle Valve Control Module J3387 - Upper part of intake manifold First tighten at lower section of intake manifold, then tighten both rear supports item 21 Disassembling and assembling Page 24-15 8 - Throttle valve control module J338-* Removing and installing Page 2415 , disassembling and assembling intake manifold upper section http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  59. 59. Motronic fuel injection and ignition system Page 13 of 37 Checking Page 24-36 9 - Connector 68-pin Switch ignition off before disconnecting or connecting connector http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  60. 60. Motronic fuel injection and ignition system Page 14 of 37 24-9 10 - Securing plate For Motronic Engine Control Module (ECM) J22011 - 10 Nm 12 - Motronic Engine Control Module (ECM) J220-* Component location: In plenum chamber, right side For fuel injection system, oxygen sensor control, EVAP canister purge regulator valve 1, engine speed limitation via Fuel Pump (FP) relay, idle stabilization, ignition as well as On Board Diagnostic http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  61. 61. Motronic fuel injection and ignition system Page 15 of 37 (OBD) Checking voltage supply Page 24101 Replace Page 24-105 13 - From brake booster 14 - To A/C system 15 - Retaining clip Check for secure fitting http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  62. 62. Motronic fuel injection and ignition system Page 16 of 37 24-10 16 - O-ring Replace if damaged 17 Engine - Coolant Temperature (ECT) Sensor G62-* For Engine Control Module (ECM) 4 pin With Engine Coolant Temperature (ECT) Sensor -G2If necessary, release pressure in cooling system before removing Checking Page 24-44 18 - Connector 4 pin 19 - Connector 2-pin For fuel injectors http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  63. 63. Motronic fuel injection and ignition system Page 17 of 37 (Cylinder 1 Fuel Injector N30through Cylinder 4 Fuel Injector N33-) 20 - 20 Nm 21 - Support Between upper part of intake manifold and cylinder head http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  64. 64. Motronic fuel injection and ignition system Page 18 of 37 24-11 22 - Gasket Always replace 23 - Lower part of intake manifold Disassembling and assembling Page 24-17 24 - Engine speed (RPM) sensor G28-* Checking Page 24-61 25 - Spacer ring http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  65. 65. Motronic fuel injection and ignition system Page 19 of 37 24-12 26 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130bank 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 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  66. 66. Motronic fuel injection and ignition system Page 20 of 37 heater for Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) Page 2428 Check Oxygen Sensor (O2S) and oxygen sensor control behind Three Way Catalytic Converter (TWC) Page 2492 27 - 4-pin harness connector Brown For Heated Oxygen Sensor (HO2S) 2 -G108and oxygen sensor heater Secured to rear engine mounts http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  67. 67. Motronic fuel injection and ignition system Page 21 of 37 24-13 28 - Heated Oxygen Sensor (HO2S) 1 G39-*, 50 Nm Component location: in front exhaust pipe 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 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  68. 68. Motronic fuel injection and ignition system Page 22 of 37 Three Way Catalytic Converter (TWC) Page 2425 Check Oxygen Sensor (O2S) and oxygen sensor control before Three Way Catalytic Converter (TWC) Page 2487 29 - 4-pin harness connector Black For Heated Oxygen Sensor (HO2S) G39- and oxygen sensor heater Secured to rear engine mounts http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  69. 69. Motronic fuel injection and ignition system Page 23 of 37 24-14 30 - Deflector 31 - To crankcase 32 - Hose To warm air collector plate at exhaust manifold 33 - Retaining ring 34 - Supply hose White arrow Secure with spring clamps From fuel filter Page 206 , item 23 35 - Return hose Blue arrow Secure with spring clamps To checkvalve on Fuel Pump (FP) unit http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  70. 70. Motronic fuel injection and ignition system Page 24 of 37 Page 20-4 , item 11 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  71. 71. Motronic fuel injection and ignition system Page 25 of 37 24-15 Intake manifold, upper part, disassembling and assembling 1 - M6 = 10 Nm, M8 = 20 Nm 2 - Throttle valve control module J338-* 8-pin connector Components of throttle valve control module J338:Throttle Position (TP) Actuator V60-, Throttle Position (TP) Sensor -G88-, Throttle Position (TP) Sensor -G69- and Closed Throttle Position (CTP) Switch -F60Checking Page 24-36 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  72. 72. Motronic fuel injection and ignition system Page 26 of 37 Adjusting accelerator pedal cable Page 2037 3 - Bracket 4 - Mounting bracket For accelerator pedal cable http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  73. 73. Motronic fuel injection and ignition system Page 27 of 37 24-16 5 - Intake Air Temperature (IAT) Sensor -G72-*, 10 Nm 2-pin connector Checking Page 24-53 6 - Upper part of intake manifold 7 - Gasket Always replace http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  74. 74. Motronic fuel injection and ignition system Page 28 of 37 24-17 Intake manifold, lower part, disassembling and assembling 1 - Retaining clip Check for secure fitting 2 - Sieve Clean if soiled 3 - Fuel pressure regulator 3 bar Checking Page 24-78 , checking fuel pressure regulator and residual pressure 4 - O-ring Always replace Lightly lubricate O-rings with clean engine oil before http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  75. 75. Motronic fuel injection and ignition system Page 29 of 37 installing 5 - Fuel injectors (N30through N33-)* Checking Page 24-65 6 - Lower part of intake manifold http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  76. 76. Motronic fuel injection and ignition system Page 30 of 37 24-18 7 - 10 Nm 8 - Fuel rail http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  77. 77. Motronic fuel injection and ignition system Page 31 of 37 24-19 Air filter, disassembling and assembling 1 - Rubber grommet 2 - Filter element 3 - Upper section of air filter 4 - O-ring Replace if damaged 5 - Mass Air Flow (MAF) Sensor G70-* 4-pin connector Checking Page 24-31 6 - 10 Nm 7 - Temperature regulator For intake air preheating Metal connector pipe or with notch toward http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  78. 78. Motronic fuel injection and ignition system Page 32 of 37 regulator flap Checking intake air preheating Page 24-97 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  79. 79. Motronic fuel injection and ignition system Page 33 of 37 24-20 8 - Gasket Replace if damaged 9 - Locking plate 10 - To intake manifold 11 - Vacuum line Check for secure seating 12 - Vacuum diaphragm 13 - Lower section of air filter 14 - Base plate http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  80. 80. Motronic fuel injection and ignition system Page 34 of 37 24-21 Safety precautions WARNING! Observe the following for all installations, especially in engine compartment due to lack of room: Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is 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. 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. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  81. 81. Motronic fuel injection and ignition system Page 35 of 37 24-22 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. If engine is to be cranked at starting RPM without starting: - Disconnect 3-pin connector from ignition coil Page 28-4 , item 8 . - Remove fuse 18 from fuse holder. Note: By removing fuse 18, voltage supply to the fuel injectors is interrupted. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  82. 82. Motronic fuel injection and ignition system Page 36 of 37 24-23 Rules of cleanliness When working on the fuel supply or fuel injection systems, the following "5 rules of cleanliness" should be carefully observed: Thoroughly clean all connections and the surrounding area before disconnecting. Place parts that have been removed on a clean surface and cover them. Use lint-free cloths only! Carefully cover over opened components or seal, if repairs are not performed 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. Do not move vehicle unless absolutely necessary. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  83. 83. Motronic fuel injection and ignition system Page 37 of 37 24-24 Technical data Engine Code ABA Idle speed1) Vehicles with manual transmission 800 to 880 RPM Vehicles with automatic transmission 830 to 910 RPM Engine Control Module (ECM) 2) System identification Motronic M5.9 Terminals at Engine Control Module (ECM) Replacement part number See Parts Catalog Engine speed (RPM) limitation 1) Replacing Engine Control Module (ECM) starting at approx. 5800 RPM Not adjustable 2) 68 Page 24-105 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  84. 84. Components of engine, checking Page 1 of 62 24-25 Components of engine, checking Oxygen sensor heater for oxygen sensor before Three Way Catalytic Converter (TWC), checking Recommended special tools and equipment V.A.G1526 Multimeter or V.A.G1715 multimeter V.A.G1594 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... 6/12/2004
  85. 85. Components of engine, checking Page 2 of 62 24-26 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 room temperature) (at If specified value is not obtained: - Replace Bank 1 Heated Oxygen Sensor (HO2S) -G39Page 26-4 , item 7 . - Erase DTC memory of Engine Control Module (ECM) Page ST26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code ST-52 . Page http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  86. 86. Components of engine, checking Page 3 of 62 24-27 If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater Page 24-27 . Checking Ground (GND) activation of oxygen sensor heating - Connect test box to control module wiring harness Page ST-11 , 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? - Also check wires for short circuit to B+ or 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) -J220Page 24-105 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  87. 87. Components of engine, checking Page 4 of 62 24-28 Oxygen sensor heater for oxygen sensorbehind Three Way Catalytic Converter (TWC), checking Recommended special tools and equipment V.A.G1526 Multimeter or V.A.G1715 multimeter V.A.G1594 Connector test kit Wiring diagram Test requirements The respective fuses of Heated Oxygen Sensor (HO2S) 2 -G108must 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... 6/12/2004
  88. 88. Components of engine, checking Page 5 of 62 24-29 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 room temperature) (at If specified value is not obtained: - Replace Bank 1 Heated Oxygen Sensor (HO2S) 2 -G108Page 26-3 , item 4 . - Erase DTC memory of Engine Control Module (ECM) Page ST26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code ST-52 . Page http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  89. 89. Components of engine, checking Page 6 of 62 24-30 If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater Page 24-30 . Checking Ground (GND) activation of oxygen sensor heating - Connect test box to control module wiring harness Page ST-11 , 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 - Also check wires for short circuit to B+ or 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) -J220Page 24-105 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  90. 90. Components of engine, checking Page 7 of 62 24-31 Mass Air Flow (MAF) sensor, checking Recommended special tools and equipment V.A.G1526 multimeter or V.A.G1715 multimeter V.A.G1594 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... 6/12/2004
  91. 91. Components of engine, checking Page 8 of 62 24-32 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-15 , Diagnostic mode 1: Check measured values; PID 5, Coolant temperature. Function test - Connect diagnostic tester Page ST-8 . - 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... 6/12/2004
  92. 92. Components of engine, checking Page 9 of 62 24-33 - 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 4.00 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 24-34 . If specified value is not obtained: - Check signal and Ground (GND) wires of Mass Air Flow (MAF) sensor Page 24-35 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  93. 93. Components of engine, checking Page 10 of 62 24-34 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: - Locate and repair open circuit using wiring diagram: Electrical Wiring Diagrams, Troubleshooting & Component Locations If voltage supply and wires are OK: - Check signal and Ground (GND) wires of Mass Air Flow (MAF) sensor Page 24-35 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  94. 94. Components of engine, checking Page 11 of 62 24-35 Checking signal and Ground wires of Mass Air Flow (MAF) Sensor - Connect test box to control module wiring harness Page ST-11 , connect test box for wiring test. - Check wires between test box and 4-pin connector -1- 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 24-19 , item 5 . - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  95. 95. Components of engine, checking Page 12 of 62 24-36 Throttle valve control module, checking Recommended special tools and equipment V.A.G1526 Multimeter or V.A.G1715 multimeter V.A.G1594 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... 6/12/2004
  96. 96. Components of engine, checking Page 13 of 62 24-37 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 20-37 , adjusting accelerator pedal cable. Coolant temperature must be at least 80 C Page ST-15 , Diagnostic mode 1: Check measured values; PID 5, Coolant temperature. Function Components of throttle valve control module J338-: Closed Throttle Position (CTP) Switch F60Throttle Position (TP) sensor -G69Throttle Position (TP) Sensor -G88Throttle Position (TP) Actuator -V60- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  97. 97. Components of engine, checking Page 14 of 62 24-38 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-8 . - 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... 6/12/2004
  98. 98. Components of engine, checking Page 15 of 62 24-39 - Check specified value of throttle valve position (absolute) at idle stop: PID 17: Diagnostic text Specified value: Throttle valve position (absolute) 0.0 to 7.0% Idle stop - 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. If specified values are not obtained: - Disconnect the 8-pin connector at the throttle valve control module. - Check resistance of throttle valve control module Page 24-40 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  99. 99. Components of engine, checking Page 16 of 62 24-40 Checking resistance - Measure resistance of Throttle Position (TP) Actuator -V60- between the terminals 1 + 2. Specified value: 3.0 to 200.0 room temperature) (at - Measure resistance of Closed Throttle Position (CTP) Switch -F60between terminals 3 + engine Ground (GND) in idle position. Specified value: Max. 5.0 temperature) (at room - Slowly open throttle valve up to Wide Open Throttle (WOT) Specified value: . If specified values are not obtained: - Replace Throttle Valve Control Module -J338Page 24-15 , item 2. - Erase DTC memory of Engine Control Module (ECM) Page ST26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code ST-52 . Page http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  100. 100. Components of engine, checking Page 17 of 62 24-41 If specified values are obtained: - Check voltage supply of throttle valve control module and wiring to control module Page 24 41 . If voltage supply and wires are OK: - Replace Motronic Engine Control Module (ECM) -J220Page 24-105 . 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. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  101. 101. Components of engine, checking Page 18 of 62 24-42 If specified values are not obtained: - Connect test box to control module wiring harness Page ST-11 , connect test box for wiring test. - 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 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  102. 102. Components of engine, checking Page 19 of 62 24-43 - 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 24-101 . - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  103. 103. Components of engine, checking Page 20 of 62 24-44 Engine Coolant Temperature (ECT) sensor, checking Recommended special tools and equipment V.A.G1526 multimeter or V.A.G1715 multimeter V.A.G1594 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... 6/12/2004
  104. 104. Components of engine, checking Page 21 of 62 24-45 Function test - Connect diagnostic tester Page ST-8 . - 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... 6/12/2004
  105. 105. Components of engine, checking Page 22 of 62 24-46 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 2447 approx. 141.0 C Short circuit to Ground (GND) Page 2449 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 climbs 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... 6/12/2004
  106. 106. Components of engine, checking Page 23 of 62 24-47 Continuation of test if indication is approx. -46.5 C: - Disconnect 4-pin connector -1- from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (-2). - Bridge terminals 1 + 3 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... 6/12/2004
  107. 107. Components of engine, checking Page 24 of 62 24-48 If indication jumps to approx 141.0 C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- Page 24-10 , item 17 . WARNING! The cooling system is under pressure. Danger of scalding when opening! - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . If indication remains at approx. -46.5 C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram Page 24-50 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  108. 108. Components of engine, checking Page 25 of 62 24-49 Continuation of test if indication is approx. 141.0 C: - Disconnect 4-pin connector -1- from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (-2). If indication jumps to approx -46.5 C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62with Engine Coolant Temperature (ECT) Sensor -G2- Page 24-10 , item 17 . WARNING! The cooling system is under pressure. Danger of scalding when opening! - Erase DTC memory of Engine Control Module (ECM) Page ST26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code ST-52 . Page http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  109. 109. Components of engine, checking Page 26 of 62 24-50 If indication remains at approx. 141.0 C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram Page 24-50 . Checking wiring - Connect test box to control module wiring harness Page ST-11 , 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 1 + socket14 Terminal 3 + socket33 Wire resistance: max. 1.5 - Also 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... 6/12/2004
  110. 110. Components of engine, checking Page 27 of 62 24-51 If no malfunctions are found in wires: - Perform a resistance measurement at Engine Coolant Temperature (ECT) Sensor -G62- terminal 1 (Ground (GND)) and 3 (signal). 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... 6/12/2004
  111. 111. Components of engine, checking Page 28 of 62 24-52 If specified value is not obtained: - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- Page 24-10 , item 17 . WARNING! The cooling system is under pressure. Danger of scalding when opening! - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220Page 24-105 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  112. 112. Components of engine, checking Page 29 of 62 24-53 Intake Air Temperature (IAT) Sensor, checking Recommended special tools and equipment V.A.G1526 Multimeter or V.A.G1715 multimeter V.A.G1594 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 ST-8 . Page - Switch ignition on. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  113. 113. Components of engine, checking Page 30 of 62 24-54 - 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 2456 approx. 141.0 C Short circuit to Ground (GND) Page 2457 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... 6/12/2004
  114. 114. Components of engine, checking Page 31 of 62 24-55 If specified value is obtained: - Disconnect 2-pin connector -1- from Intake Air Temperature (IAT) Sensor -G72- (-2-). - Remove Intake Air Temperature (IAT) Sensor -G72- and re-connect to connector. - Seal threaded bore for sensor. - Note value of intake manifold temperature. - Spray the sensor with commercially available chilling spray while observing the temperature value. The temperature must decrease. - End diagnosis and switch ignition off. If the intake manifold temperature does not drop: - Replace Intake Air Temperature (IAT) Sensor -G72Page 24-16 , item 5 . - Erase DTC memory of Engine Control Module (ECM) Page ST26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code ST-52 . Page http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  115. 115. Components of engine, checking Page 32 of 62 24-56 Continuation of test if indication is 46.5 C: - Disconnect 2-pin connector -1- from Intake Air Temperature (IAT) Sensor -G72- (-2-). - 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 -G72Page 24-16 , item 5 . - Erase DTC memory of Engine Control Module (ECM) Page ST26 , Diagnostic mode 4: Reset/erase diagnostic data. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  116. 116. Components of engine, checking Page 33 of 62 24-57 - Generate readiness code Page ST-52 . If indication remains at approx -46.5 C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram Page 24-58 . Continuation of test if indication is 141.0 C: - Disconnect 2-pin connector -1- from Intake Air Temperature (IAT) Sensor -G72- (-2-). If indication jumps to approx. -46.5 C: - End diagnosis and switch ignition off. - Replace Intake Air Temperature (IAT) Sensor G72- Page 24-16 , item 5 . - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  117. 117. Components of engine, checking Page 34 of 62 24-58 If indication remains at 141.0 C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram Page 24-58 . Checking wiring - Connect test box to control module wiring harness Page ST-11 , connect test box for wiring test. - Check wires between test box and 2-pin connector 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: http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  118. 118. Components of engine, checking Page 35 of 62 24-59 If no malfunctions are found in wire: - Measure resistance at Intake Air Temperature (IAT) Sensor -G72- (-2), terminals 1 (signal) and 2 (Ground (GND)). Range A displays resistance values for the temperature range of 0 to 0.50 C, range B displays resistance values for the temperature range of 50 to 0.100 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... 6/12/2004
  119. 119. Components of engine, checking Page 36 of 62 24-60 If specified value is not obtained: - Replace Intake Air Temperature (IAT) Sensor G72- Page 24-16 , item 5 . - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220Page 24-105 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  120. 120. Components of engine, checking Page 37 of 62 24-61 Engine speed (RPM) sensor, checking Function The Engine Speed (RPM) Sensor -G28detects 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.G1526 Multimeter or V.A.G1715 Multimeter V.A.G1594 Connector test kit Wiring diagram http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  121. 121. Components of engine, checking Page 38 of 62 24-62 Test sequence - Disconnect 3-pin harness connector 2- to engine speed (RPM) sensor -1-. - Measure sensor resistance between terminals 2 + 3 at connector to sensor. Specified value: 480 to 1000 - Check sensor for short circuit between terminals 1 + 2 as well as 1 + 3. Specified value: http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  122. 122. Components of engine, checking Page 39 of 62 24-63 If specified values are not obtained: - Replace Engine Speed (RPM) Sensor -G28Page 24-11 , item 24 . - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . If no DTC is found on sensor: - Connect test box to control module wiring harness Page ST-11 , connect test box for wiring test. - 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: http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  123. 123. Components of engine, checking Page 40 of 62 24-64 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) -J220Page 24-105 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  124. 124. Components of engine, checking Page 41 of 62 24-65 Fuel injectors, checking Recommended special tools and equipment V.A.G1526 Multimeter or V.A.G1715 multimeter V.A.G1527 Voltage test lamp V.A.G1594 Connector test kit Wiring diagram Test requirements The respective fuses of fuel injectors (-N30- to -N33-) 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... 6/12/2004
  125. 125. Components of engine, checking Page 42 of 62 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 must be OK, checking Page 24-61 . Ignition switched off. Test sequence Observe safety precautions Observe rules for cleanliness Page 24-21 . Page 24-23 . - Remove intake manifold upper section 24-8 , item 7 . Page - Disconnect fuel injector connectors. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  126. 126. Components of engine, checking Page 43 of 62 24-67 Resistance values of fuel injectors, checking - Test resistance of fuel injectors between terminals. Specified value: 14.0 to 20.0 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 Page 24-17 , item 5 . Note the following when installing the 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. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  127. 127. Components of engine, checking Page 44 of 62 24-68 - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . Checking voltage supply - 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 1 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  128. 128. Components of engine, checking Page 45 of 62 24-69 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. If LED does not flicker: - Connect test box to control module wiring harness Page ST-11 , connect test box for wiring test. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  129. 129. Components of engine, checking Page 46 of 62 24-70 - Check wires between test box and 2pin 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 - Check wires for short circuit to B+ or Ground (GND). Specified value: If there is no malfunction in wire connection: - Replace Motronic Engine Control Module (ECM) -J220Page 24105 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  130. 130. Components of engine, checking Page 47 of 62 24-71 Injection quantity and proper seal of fuel injectors, checking Recommended special tools and equipment V.A.G1348/3A remote control with V.A.G1348/32 adapter cable V.A.G 1602 tester for quantity of injected fuel Not illustrated: V.A.G1594A connector test kit http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  131. 131. Components of engine, checking Page 48 of 62 24-72 Test requirement Fuel pressure must be OK, check Page 24-77 , fuel pressure regulator and retaining pressure, checking. Test sequence WARNING! Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. - Remove intake manifold upper section 24-8 , item 7 . Page Note: Seal the intake channels in lower part of intake manifold using a clean rag. - Disconnect fuel injector connectors. - Remove fuel rail with fuel injectors and support Page 24-17 , disassembling and assembling lower section of intake manifold. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  132. 132. Components of engine, checking Page 49 of 62 24-73 Checking Proper Seal - Remove Fuel Pump (FP) Relay -J17from 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 respective 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 -J17into relay carrier. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  133. 133. Components of engine, checking Page 50 of 62 24-74 If fuel loss is greater: - Replace malfunctioning fuel injector 17 , item 5 . 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. 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-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  134. 134. Components of engine, checking Page 51 of 62 24-75 Checking injection quantity - Insert a fuel injector to be tested into a measuring tube of V.A.G1602 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.G1348/3 remote control with V.A.G1348/3-2 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... 6/12/2004
  135. 135. Components of engine, checking Page 52 of 62 24-76 - Bridge terminals 4 + 6 on relay carrier using respective 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: Also 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: 85 to 105 ml per injector - Disconnect the connection between relay carrier terminals. - Insert Fuel Pump (FP) Relay -J17- into relay carrier. If the measured value of one or more fuel injectors is below or above the indicated specified value: - Replace malfunctioning fuel injector 17 , item 5 . Page 24- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  136. 136. Components of engine, checking Page 53 of 62 24-77 Note the following when installing the 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-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  137. 137. Components of engine, checking Page 54 of 62 24-78 Fuel pressure regulator and residual pressure, checking Function The fuel pressure regulator controls the fuel pressure as a function of the Manifold Absolute Pressure (MAP). Recommended special tools and equipment V.A.G 1318 pressure gauge V.A.G 1318/10 adapter V.A.G 1318/11 adapter V.A.G 1318/16 hose adapter VAS5024A assembly tool for springtype clamps http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  138. 138. Components of engine, checking Page 55 of 62 24-79 Test requirements 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-. Delivery quantity and check-valve of Fuel Pump (FP) OK, check Page 20-15 , Fuel Pump (FP), checking. Ignition switched off. Test sequence Observe safety precautions 21 . Observe rules for cleanliness 24-23 . Page 24Page - Remove fuse no. 18 from fuse holder. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  139. 139. Components of engine, checking Page 56 of 62 24-80 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! - Disconnect fuel supply line -1- from connection on fuel rail -2- and connect to adapter V.A.G 1318/10 at pressure gauge V.A.G 1318 - Use a rag to catch escaping fuel. - Connect pressure gauge (V.A.G 1318) with adapters ((V.A.G 1318/11) and ((V.A.G 1318/16) to fuel rail -2-. - Open shut-off valve of pressure gauge. The lever points in the direction of flow (arrow). http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  140. 140. Components of engine, checking Page 57 of 62 24-81 - Re-insert fuse 18 (fuel pump) into fuse holder. - Start engine and let run at idle. - Measure fuel pressure. Specified value: approx. 2.5 bar positive pressure - Disconnect vacuum hose -1- from connecting piece -2-. Fuel pressure should rise to approx. 3.0 bar positive pressure rise. - Switch ignition off. Note: If fuel should escape at the vacuum connection of the pressure regulator, replace fuel pressure regulator Page 24-17 , item 3 . - Check for proper seal and residual pressure. Observe pressure drop on pressure gauge for this. After 10 minutes at least 2.0 bar positive pressure should still be present. If residual pressure falls below 2 bar positive pressure: - Start engine and let run at idle. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  141. 141. Components of engine, checking Page 58 of 62 24-82 - Wait until pressure has dropped, and then switch off ignition. Simultaneously close shut-off valve of pressure gauge (lever perpendicular to direction of flow arrow-). - Observe pressure drop on pressure gauge. If pressure does drop again: - Test check-valve of Fuel Pump (FP) Page 20-15 , Fuel Pump (FP), checking. If pressure does not drop: - Open stop valve of pressure gauge (lever in direction of flow -arrow-). - Start engine and let run at idle. - Wait until pressure has dropped, and then switch off ignition. Simultaneously pinch return hose tightly together. If pressure does not drop: - Replace fuel pressure regulator Page 24-17 , item 3 . - Erase DTC memory of Engine Control Module (ECM) Page ST26 , Diagnostic mode 4: Reset/erase diagnostic data. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  142. 142. Components of engine, checking Page 59 of 62 24-83 - Generate readiness code Page ST-52 . If pressure does drop again: - Check whether line connections, O-rings in fuel distributor, and fuel injectors are properly sealed. - Check pressure gauge for proper seal. Note: Before removing pressure gauge, put cleaning rags back around line connection which is to be disconnected. - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  143. 143. Components of engine, checking Page 60 of 62 24-84 Intake system for leaks (false air), checking Checking with engine leak detection spray Recommended special tools and equipment Engine leak detection spray G 001 800 A1 Test requirements 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-. Coolant temperature must be at least 80 C Page ST-15 , Diagnostic mode 1: Check measured values; PID 5, Coolant temperature. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  144. 144. Components of engine, checking Page 61 of 62 24-85 Test sequence Note: Vacuum in the intake system sucks in the leak detection spray with false air. Leak detection spray decreases ignition quality of the fuel mixture. This causes a drop in engine speed and changes the value produced by the Heated Oxygen Sensor (HO2S). It is absolutely necessary to follow the safety precautions listed on the can. - Connect diagnostic tester Page ST-8 . - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the following measured values: PID 06: Short time gasoline-air ratio bank 1 PID 12: Engine rotations per minute (RPM) - Observe the short time gasoline-air ratio bank 1 as well as engine speed. - Spray intake system parts with engine leak detection spray in a systematic manner. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  145. 145. Components of engine, checking Page 62 of 62 24-86 If engine speed drops or if the short-term gasoline-air ratio changes: - End diagnosis and switch ignition off. - Check sprayed part of intake system for leaks, and repair the malfunction. - Erase DTC memory of Engine Control Module (ECM) Page ST-26 , Diagnostic mode 4: Reset/erase diagnostic data. - Generate readiness code Page ST-52 . http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
  146. 146. Function tests Page 1 of 13 24-87 Function tests Oxygen sensor and oxygen sensor regulation before catalytic converter, checking Recommended special tools and equipment V.A.G1526 Multimeter or V.A.G1715 multimeter V.A.G1594 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 Battery voltage must be at least 11.5 volts. Ground (GND) connections between engine and chassis must be OK. 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... 6/12/2004

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