volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling intake manifold - Upper part > < Fitting locations overview
Motronic fuel injection and ignition system 08.95 ä
Motronic injection and ignition system
Servicing injection part

Servicing ignition part

=> Repair group 28

Notes:

  • ◆ Fuel hoses in engine compartment must only be secured with spring type clips. The use of clamp or screw type clips is not permissible.
  • ◆ 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 01-72 .
  • ◆ 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.
  • ◆ Do not use contact sprays or similar agents in the area of the connector for Lambda probes. To function correctly Lambda probes require reference air, which they receive via the cable. If contact spray gets into the Lambda probe via this path it will lead to damage/malfunctions.
  • ◆ During some checks it can happen 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 01-11 , interrogating fault memory

Safety precautions

Rules for cleanliness => Page 24-22

Technical data => Page 24-23

 
N24-0290
  • Air cleaner
    • ◆ Dismantling and assembling => Page 24-18
  • Connector
    • ◆ 4 pin
    • ◆ For air mass meter (G70)
  • To activated charcoal filter solenoid valve 1 (N80)*/**
    • ◆ Activated charcoal filter system

=> Repair group 20; removing and installing parts of the fuel supply system; servicing activated charcoal filter system

  • Intake hose
  • Crankcase breather pressure regulating valve
  • Connector
    • ◆ 8 pin
    • ◆ For throttle valve control part (J338)
 
N24-0290
  • Intake manifold - upper part
    • ◆ First tighten to intake manifold lower part and then to both rear supports
      => Page 24-10 , Item 21
    • ◆ Dismantling and assembling => Page 24-18
  • Throttle valve control part (J338)*
    • ◆ If replaced perform basic setting => Page 24-88
  • Connector
    • ◆ 68 pin
    • ◆ Only disconnect or connect with ignition switched off
  • Securing plate
    • ◆ For Motronic control unit (J220)
  • 10 Nm
 
N24-0290
  • Motronic control unit (J220)*
    • ◆ Location: in plenum chamber, right
    • ◆ For injection system, Lambda regulation, activated charcoal filter solenoid valve 1, speed governing via fuel pump relay, idling speed stabilization, ignition and self diagnosis
    • ◆ Check control unit coding
      => Page 01-9
    • ◆ If replaced perform basic setting => Page 24-88
  • To brake servo
  • To air conditioner
  • Retaining clip
    • ◆ Check seated securely
  • O ring
    • ◆ Renew if damaged
 
N24-0290
  • Coolant temperature sender (G62)*
    • ◆ Black, with temperature gauge sender (G2)
    • ◆ For Motronic
    • ◆ Checking => Page 24-92
    • ◆ If necessary before removing, release pressure from cooling system
  • Connector
    • ◆ 4 pin
    • ◆ Wiring chamber 1 and wiring chamber 3 for G62
  • Connector
  • 20 Nm
  • Support
    • ◆ Between intake manifold upper part and cylinder head
  • Seal
    • ◆ Renew
 
N24-0290
  • Intake rail - lower part
    • ◆ Dismantling and assembling => Page 24-17
  • Engine speed sender (G28)*
  • Spacer ring
  • Lambda probe after catalyst (G108)*, 50 Nm
    • ◆ Fitting location: catalyst
    • ◆ Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
    • ◆ Checking Lambda probe and Lambda control after catalyst => Page 24-44
    • ◆ Probe heating voltage supply via fuel pump relay (J17)
    • ◆ Checking Lambda probe heating => Page 24-51
 
N24-0290
  • Connector
    • ◆ Brown, 4 pin
    • ◆ For Lambda probe and Lambda probe heating after catalyst
    • ◆ Secured to rear engine mounting
  • Lambda probe before catalyst (G39)*, 50 Nm
    • ◆ Fitting location: catalyst
    • ◆ Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
    • ◆ Checking Lambda probe and Lambda control before catalyst=> Page 24-27
    • ◆ Probe heating voltage supply via fuel pump relay (J17)
    • ◆ Checking Lambda probe heating => Page 24-37
 
N24-0290
  • Connector
    • ◆ Black, 4 pin
    • ◆ For Lambda probe and Lambda probe heating after catalyst
    • ◆ Secured to rear engine mounting
  • Deflector
  • To crankcase
  • Hose
    • ◆ To warm air collection plate on exhaust manifold

=> Repair group 26; Removing and installing parts of exhaust system

  • Retaining ring
 
N24-0290
  • Supply hose
    • ◆ White arrow
    • ◆ Secure with spring-type clips
    • ◆ From fuel delivery unit in fuel tank
  • Return hose
    • ◆ Blue arrow
    • ◆ Secure with spring-type clips
    • ◆ To fuel tank

Dismantling and assembling intake manifold - Upper part > < Fitting locations overview