Volkswagen Workshop Service and Repair Manuals

• ◆ Only the components which specifically relate to the ignition system are dealt with here. For the other components of the injection and ignition system => Repair group 24.
• ◆ Disconnecting and connecting the battery must only be done with the ignition switched off, otherwise the engine control unit could be damaged.
• ◆ The engine control unit is equipped with self diagnosis.
• ◆ Components marked with * are checked via the self diagnosis.
  , interrogating fault memory
• ◆ For trouble-free operation of the electrical components a voltage of at least 11.5 V is necessary.
• ◆ During some checks it is possible that the control unit will recognise and store a fault. Therefore after completing all checks and repairs the fault memory must be interrogated and if necessary erased.
  => Page 01-13 , interrogating fault memory
• ◆ If the engine starts, runs for a short period and then stops, after fault finding, repairs or component tests, then the fault may lie with the immobilizer which is blocking the engine control unit. The fault memory must be interrogated and if necessary the control unit matched => Page 24-122 .

Safety precautions => Page 28-6

Test data, spark plugs => Page 28-7

Note:

Motronic control unit (J220)* with connector => Page 24-8 , item 2

• Hall sender (G40)*
• ◆ Checking => Page 28-8
• ◆ Note distance rings
• 10 Nm
• Connector
• ◆ 5 pin
• ◆ For ignition transformer (N152)
• H.T. cable
• ◆ Check for continuity
• Suppressor
• ◆ 0.6...1.4 kω
• Ignition transformer (N152)*
• ◆ With ignition cable identification, do not interchange
• ◆ Checking => Page 28-11

• Camshaft sprocket cover
• ◆ Removing and installing

=> Repair group 15; removing and installing cylinder head

• Connector
• ◆ 3 pin
• 20 Nm
• ◆ Tightening torque influences the function of the knock sensor
• Knock sensor 2 (G66)*
• ◆ Motronic with distributor-less ignition
  => Page 28-4 , item 10
• ◆ Motronic with distributor
  => Page 28-23 , item 15
• ◆ Fitting location: Cylinder block intake side
• Sender wheel
• ◆ For Hall sender (G40)
• ◆ Contact surface on camshaft sprocket must be dry
• ◆ If the sender wheel has been removed, after installing check timing:

=> Repair group 13; dismantling and assembling engine; adjusting timing

• Knock sensor 1 (G61)*
• ◆ Fitting location: Cylinder block exhaust side
• ◆ Motronic with distributor
  => Page 28-22 , item 12
• 100 Nm
• ◆ To remove and installing counter-hold with 24 mm OJ spanner on camshaft
• ◆ Oil contact surface of bolt head
• Spark plug, 25 Nm
• ◆ Remove and install with 3122B
• ◆ Type and electrode gap
  => Page 28-7 , test data, spark plugs
• Spark plug connector
• ◆ Use 3277 when pulling off and pressing on
• ◆ 4...6 kω
• O ring
• ◆ Renew if damaged
• Connector
• ◆ 3 pin
• ◆ Hall sender (G40)