Volkswagen Workshop Service and Repair Manuals

Servicing ignition part=>Repair group 28

Notes:

• ◆ The control unit for the fuel injection and ignition system is equipped with a fault memory. Before carrying out repairs, adjustment work and fault finding the fault memory must be interrogated and the vacuum connections checked (outside air).
• ◆ Components marked with * are checked via the self diagnosis.
  , interrogating fault memory
• ◆ Components marked with ** are checked via the final control control diagnosis => Page 01-16 .
• ◆ Always renew spring-type hose clips with screw or windlass-type hose clips.
• ◆ For trouble-free operation of the electrical components a voltage of at least 11.5 V is necessary.
• ◆ Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the engine and damage the Lambda probe.

Safety precautions

Rules for cleanliness => Page 24-21

Technical data => Page 24-22

Self diagnosis and electrical check of the injection and ignition system => Repair group 01

Checking intake system for leaks (unmetered air) => Page 24-53

• Air cleaner
• ◆ Dismantling and assembling => Page 24-13
• Connector
• Activated charcoal filter solenoid valve 1 (N80)
• ◆ Activated charcoal filter system

=> Repair Group 20; Removing and installing parts of fuel supply system; Removing and installing activated charcoal filter system.

• Hose
• ◆ From warm air collector on exhaust manifold
• 15 Nm
• Plug
• 10 Nm

• Air intake elbow
• Seal
• Injection unit
• ◆ Servicing => Page 24-15
• Return pipe
• Supply pipe
• Cable guide
• 20 Nm
• Support bracket
• Warm air collector plate
• To coolant pipe
• Vacuum connection
• ◆ To brake servo
• Intake manifold

• Seal
• ◆ Renew
• 25 Nm
• Retainer
• Retaining ring
• Retaining clip
• Connection
• O ring
• ◆ Renew
• Coolant temperature sender (G62)*
• ◆ With coolant temperature gauge sender (G2)
• ◆ If necessary before removing, release pressure from cooling system
• ◆ Checking

• Connector
• ◆ Only disconnect or connect with ignition switched off
• ◆ Unlatch to disconnect
• Mono-Motronic control unit (J257)
• ◆ For injection system, Lambda regulation, activated charcoal filter solenoid valve, speed governing via fuel pump relay, intake air preheating control, ignition and self diagnosis
• ◆ Location: in plenum chamber, right
• Lambda probe (G39)*, 50 Nm
• ◆ Location: in front exhaust pipe
• ◆ Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
• ◆ Note different version
  => Page 24-20 , Fig. 1

• Connector
• ◆ For Lambda probe (G39)
• ◆ 2 pin connector for unheated Lambda probe
• ◆ 4 pin connector for heated Lambda probe
• ◆ Check Lambda probe heating voltage supply between contacts -1- and -2- with engine running:
       Specification:
       approx. battery voltage
• ◆ Check Lambda probe heating at Lambda probe connector (white wiring) for continuity
• ◆ Contact 3 - Lambda probe screening
• ◆ Contact 4 - Lambda control