Volkswagen Workshop Service and Repair Manuals

The components A, B C and D are not shown on the illustration.

•     A -    Brake pedal switch (F47) or brake light switch (F)
• ◆ Together in one housing in the footwell
•     B -    Accelerator pedal position senders (G79 and G185)
• ◆ In footwell at accelerator pedal
•     C -    Clutch pedal switch (F36)
• ◆ In footwell
•     D -    Fuel pressure regulator
• ◆ On fuel filter in fuel tank
• ◆ Checking => Page 24-38

• Inlet camshaft timing adjustment valve (N205)
• ◆ is controlled by the engine control unit
• Combi-valve
• ◆ Secondary air system
• Hall sender (G40)
• ◆ In cylinder head cover
• 81-pin connector
• ◆ Only disconnect or connect with ignition switched off
• ◆ Release to disconnect
• Engine control unit
• (Motronic control unit -J220-)
• ◆ On replacement, the control unit must be matched to the electronic immobilizer => Page 24-43, adapting components
• ◆ Fitting location: In plenum chamber
• ◆ Renew => Page 24-41

• 40-pin connector
• ◆ Only disconnect or connect with ignition switched off
• ◆ Release to disconnect
• Coolant temperature sender (G62)
• ◆ For engine control unit
• ◆ Gold plated contacts
• ◆ Release pressure in coolant system if necessary before removing components
• Activated charcoal canister solenoid valve 1 (N80)
• ◆ Activated charcoal canister system=> Page 20-55:
• Intake manifold
• Upper part:
• ◆ Dismantling and assembling => page 24-13
• Lower part:
• ◆ Dismantling and assembling => page 24-15

• Throttle valve control part (J338)
• ◆ When renewing, adapt (match) engine control unit to throttle valve control part =>Seite 24-43, adapting components
• ◆ 6-pin connector
• ◆ Gold plated contacts
• Heater element (N79)
• ◆ For crankcase breather
• ◆ Checking => page 24-17, item 1
• Air mass meter (G70) with intake air temperature sender (G42)
• ◆ Gold plated contacts
• Protective housing for relays
• ◆ Secondary air pump relay (J299)
• ◆ Motronic current supply relay (J271)
• ◆ Relay assignment in protective housing=> fig.1

• Air cleaner
• ◆ Dismantling and assembling => page 24-17
• Main fuses
• Lambda probe downstream of catalytic converter (G130), 50Nm
• ◆ Fitting location: In rear of catalytic converter
• ◆ When renewing erase fault memory => page 24-46
• ◆ Removing and installing => page 26-1
• 4-pin connector
• ◆ Brown
• ◆ Connector contacts 3 and 4 are gold plated
• ◆ For Lambda probe after catalytic converter (G130) and Lambda probe heating (Z29)
• ◆ Fitting location: On right on underside of vehicle => Fig.2

• Centre Lambda probe catalyst (G465), 50 Nm
• ◆ Fitting location: In centre catalyst
• ◆ When renewing erase fault memory => page 24-46
• ◆ Removing and installing => page 26-1
• 4-pin connector
• ◆ black
• ◆ Connector contacts 3 and 4 are gold plated
• ◆ For centre Lambda probe catalyst (G465) and Lambda probe heater (Z59)
• ◆ Fitting location: On right on underside of vehicle => Fig.2

• Exhaust gas temperature sender 1(G235), 45 Nm
• ◆ Fitting location: In exhaust pipe
• ◆ When renewing erase fault memory => page 24-46
• ◆ Removing and installing => page 26-1
• Lambda probe upstream of catalytic converter (G39), 50Nm
• ◆ Fitting location: In exhaust manifold
• ◆ When renewing erase fault memory => page 24-46
• ◆ Removing and installing => page 26-1

• 6-pin connector
• ◆ Black for Lambda probe before catalytic converter (G39) and Lambda probe heater (Z19)
• ◆ Gold plated contacts
• ◆ Fitting location: On right on underside of vehicle => Fig.2
• 2-pin connector
• ◆ Black for exhaust gas temperature sender (G235)
• ◆ Gold plated contacts
• ◆ Fitting location: On right on underside of vehicle => Fig.2
• Knock sensor 1 (G61)
• ◆ Gold plated contacts
• ◆ Torque setting:
  => Page 28-3, item 9
• Knock sensor 2 (G66)
• ◆ Next to ignition transformer
• ◆ Gold plated contacts
• ◆ Torque setting:
  => Page 28-3, item 9

• Injector (N30...N33)
• ◆ Air shrouded
• ◆ Checking quantity injected and for leaks
• Secondary air pump motor (V101)
• ◆ Secondary air system
• Engine speed sender (G28)
• ◆ Torque setting 10 Nm
• Ignition coils with final output stages (N70, N127, N291, N292)
• ◆ => Page 28-2, item 2

→ Fig.1    Position of relays in protective housing (on left in engine compartment)

•     1 -    Secondary air pump relay (J299),
  Distinguishing features: Control number 100
•     2 -    Motronic current supply relay (J271),
  Distinguishing features: Control number 428

Notes:

• ◆ The relay locations may differ depending on level of equipment.
  For latest control numbers and fitting locations:

=> Current flow diagrams, Electrical fault finding and Fitting locations

• ◆ Disconnect battery earth strap first if tools are required to pull relays or control units out of the relay plate.

• ◆ Before disconnecting battery earth strap obtain code for radios with anti-theft coding.

→ Fig.2    Connectors´ fitting location

•     1 -    Protective housing, on vehicle underside right side
•     2 -    For exhaust gas temperature sender 1 (G235)
•     3 -    For Lambda probe before catalytic converter (G39)
•     4 -    For centre Lambda probe catalyst (G465)
•     5 -    For Lambda probe after catalyst (G130)