Page 1 of 25 28-2 Motronic ignition system, servicing Note: Motronic Engine Control Module (ECM) J220* with connector page 24-9, item 16. 1 - Highvoltage ignition cable Ignition secondary circuit Check for continuity 2 - Suppressor Resistance: 0.6-1.4 k 3 - Ignition coil terminal 1 4 - Ignition coil terminal 15 5 - Ignition coil power output stage - N157-* Checking
Page 2 of 25 page 28-20 6-10 Nm (7 ft lb) 7 - Ignition coil -N152- Checking page 28-19
Page 3 of 25 28-3 8 - Harness connector 3-pin 9 - Ground (GND) strap 10 - Knock Sensor (KS) 1 - G61-* 11-20 Nm (15 ft lb) Tightening torque influences knock sensor function 12 - Spark plug connector Use 3277 when pulling off and pushing on Resistance: 4-6 k 13 - Spark plug Tightening torque: 30 Nm (22 ft lb) Remove and install with 3122B
Page 4 of 25 Spark plug type and electrode gap page 28-7 14-25 Nm (18 ft lb) 15 - Clamp
Page 5 of 25 28-4 16 - O-ring Replace if damaged 17 - Distributor with Camshaft Position (CMP) sensor - G40-* Installing page 28-8 Checking CMP sensor page 28-15 18 - Dust cap 19 - Rotor arm Marking: R1 Resistance: 0.6-1.4 k 20 - Distributor cap Check for cracks and signs of tracking Check contact wear Clean before fitting
Page 6 of 25 Check carbon brush for wear and freedom of movement 21 - Shielding cap
Page 7 of 25 28-5 Safety precautions WARNING! Be alert when working on or near the engine. High ignition secondary voltage can cause serious personal injury and damage vehicle components. DO NOT touch or disconnect ignition system wires when the engine is running or being cranked at starting RPM. DO NOT operate the starter if the fuel injectors have been removed. Be sure the ignition is switched OFF, when: Disconnecting ignition wires Disconnecting fuel injection system wiring Connecting or disconnecting test equipment leads Disconnecting the battery Washing the engine or engine compartment. BEFORE cranking the engine at starting RPM (such as for compression testing) disable the ignition and fuel injection systems: Disconnect the ignition coil power output stage. Disconnect harness connectors from all fuel injectors.
Page 8 of 25 After the work is completed, erase Diagnostic Trouble Code (DTC) memory.
Page 9 of 25 28-6 CAUTION! BEFORE disconnecting the battery: Stop the engine. Be sure the ignition is switched OFF (also applies when connecting the battery). Failure to do so may damage the Engine Control Module (ECM). Be sure of the proper radio code (for vehicles equipped with coded anti-theft radio). Be sure the battery negative (-) cable is disconnected, when: Working on the electrical system Resistance (spot) welding or electric arc welding anywhere on the vehicle. When connecting and disconnecting electrical test equipment (LED voltage tester, multimeter, etc.): Be sure the ignition is switched OFF. Use correct adapters from the VW 1594 connector test kit. For any work affecting the Engine Control Module (ECM): BEFORE disconnecting the ECM harness connector, switch the ignition OFF and WAIT at least 20 seconds. Failure to do so may damage the ECM. DO NOT connect any outside voltage source to stimulate an output signal at the ECM.
Page 10 of 25 28-7 Technical data, spark plugs Engine code Ignition timing1) ABA Checking page 24-23 Firing order 1-3-4-2 Spark plugs1) VW/Audi 101 000 044 AA Manufacturer's designation Electrode gap 2) FR 8 DS 0.8 mm Tightening torque (0.031 in.) 30 Nm (22 ft lb) 1) Not adjustable 2) Gap between ground electrodes and center electrode insulation
Page 11 of 25 28-8 Distributor, removing and installing Special tools, testers and auxiliary items Pin wrench Matra V159 Note: Torque wrench VAG 1331 (5-50 Nm) The Motronic Engine Control Module (ECM) requires the Cyl. 1 TDC signal from the camshaft position sensor in the distributor in order to allocate the fuel injection and knock sensor systems according to the firing order. Checking Cyl.1 Top Dead Center (TDC) markings - Set flywheel -A- or automatic transmission drive plate -B- to align marks for Cyl.1 TDC.
Page 12 of 25 28-9 Engine removed Set vibration damper (V-belt pulley) to mark for Cyl.1 TDC. Mark on camshaft sprocket must align with arrow on cylinder head cover.
Page 13 of 25 28-10 Mark on distributor housing must align with mark on rotor arm or camshaft position sensor cover. Removing Crankshaft and camshaft in Cyl.1 TDC position - Remove distributor. Installing - Align oil pump shaft drive lug parallel to crankshaft.
Page 14 of 25 28-11 - Install distributor. Note: Pins on distributor must point toward mounting bolt threaded hole (arrow). When installing, turn the rotor arm slightly the the right of the distributor marking (clockwise). When inserting the distributor and meshing the drive gears, the rotor arm will turn back toward the marking. Mark on distributor housing must align with mark on rotor arm or camshaft position sensor cover. - Tighten distributor securing bolt. Tightening torque: 25 Nm (18 ft lb) If the markings cannot be aligned correctly: - Loosen toothed drive belt tensioner roller and remove toothed belt from camshaft sprocket.
Page 15 of 25 28-12 - Turn intermediate shaft sprocket with toothed drive belt (in direction of arrows) until rotor arm aligns with markings for Cyl.1 on distributor housing. (Toothed belt slides over crankshaft sprocket.) Note: Mark on distributor housing must align with mark on rotor arm or camshaft position sensor cover. - Position toothed drive belt onto tensioner roller and camshaft sprocket. For easier installation of the toothed belt, loosen the tensioner roller lock nut by only approx. one thread.
Page 16 of 25 28-13 - Turn tensioner with pin wrench (e.g. Matra V159) in direction of arrow to adjust toothed drive belt tension. It must be just possible to turn the toothed belt through 90 with the thumb and forefinger in the center between camshaft and intermediate shaft sprockets. - Tighten tensioner lock nut. Tightening torque: 45 Nm (33 ft lb) - Rotate crankshaft two full turns and check adjustment. - Check distributor housing and rotor arm markings. - Install upper toothed drive belt cover. - Before installing, clean distributor cap, check for cracks and signs of tracking, and replace if necessary.
Page 17 of 25 28-14 Ignition timing control, checking Special tools, testers and auxiliary items VAG 1767 ignition tester, or VAG 1367 ignition tester with VAG 1367/8 HT pick-up clamp Check conditions Engine oil temperature at least 80 C (176 F) Test sequence - Connect VAG 1767 ignition tester, or VAG 1367 ignition tester with VAG 1367/8 HT pick-up clamp. - Start engine and run at idle speed. - Set ignition tester to 3000 RPM. - Slowly increase engine speed to slightly above 3000 RPM until the ignition timing (advance figure) is indicated. Specification: 29-34 before TDC If the specification is not attained: - Replace Motronic Engine Control Module (ECM) J220 page 24-9, item 16.
Page 18 of 25 28-15 Camshaft Position (CMP) sensor, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram Test sequence - Disconnect harness connector from sensor (distributor). - Connect multimeter to measure voltage at ou connector terminals using adapter cables fro VW 1594. - Switch ignition on. Specification: min. 4.5 volts - Switch ignition off. If the specification is not attained: - Connect VAG 1598/18 test box to ECM wirin harness.
Page 19 of 25 28-16 - Check wiring for open circuits between test box and 3-pin connector, according to wiring diagram. Terminal 1 and test box socket 56 Terminal 2 and test box socket 44 Terminal 3 and test box socket 41 Wire resistance: Max. 1.5 - Additionally check wires for short circuits to one another. Terminal 3 and test box socket 44 Terminal 3 and test box socket 56 Terminal 2 and test box socket 56 Specification: (no continuity) If no wiring malfunction is detected and voltage was present between terminals 1 and 3: - Replace distributor with CMP sensor page 28-4, item 17. If no wiring malfunction is detected and no voltage was present between terminals 1 and 3: - Replace Motronic Engine Control Module (ECM) J220 page 24-9, item 16.
Page 20 of 25 28-17 Knock sensor, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Wiring diagram Test sequence - Disconnect brown 3-pin harness connector -2- from knock sensor 1 G61 socket -1-. - Measure resistance between terminals 1 and 2, 1 and 3 and 2 and 3 at knock sensor connector socket. Specification: (no continuity) If the specification is attained: - Connect VAG 1598/18 test box to ECM wiring harness.
Page 21 of 25 28-18 - Check wiring between test box and 3-pin connector for open circuit according to wiring diagram. Terminal 1 and test box socket 34 Terminal 2 and test box socket 33 Terminal 3 and test box socket 56 Wire resistance: Max. 1.5 - Additionally check wires for short to one another. Terminal 3 and test box socket 34 Terminal 3 and test box socket 33 Terminal 2 and test box socket 34 Specification: (no continuity) If no wiring malfunction is detected: - Loosen knock sensor and tighten again to 20 Nm (15 ft lb). If the malfunction is still present (stored again in DTC memory): - Replace knock sensor.
Page 22 of 25 28-19 Ignition coil, checking Special tools, testers and auxiliary items Multimeter (Fluke 83 or equivalent) VW 1594 connector test kit Test sequence - Disconnect harness connector and high-volta cable from ignition coil N152. - Check primary resistance with between terminals 1 and 15 with multimeter. Specification: 0.5-1.2 - Check secondary resistance between termin 4 and 15 with multimeter. Specification: 3-4 k If the specifications are not attained: - Replace ignition coil N152.
Page 23 of 25 28-20 Ignition coil power output stage, checking Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VAG 1527B voltage tester VW 1594 connector test kit Wiring diagram Checking voltage supply - Disconnect 3-pin harness connector from ignition coil. - Connect multimeter to measure voltage betw connector terminals 1 and 3 using adapter cables from VW 1594 test kit. - Switch ignition on. Specification: Min. 9 volts If no voltage is present: - Switch ignition off. - Check wire for open circuit between 3-pin connector terminal 1 and ground, according t wiring diagram. Wire resistance: Max. 1.5
Page 24 of 25 28-21 - Connect VAG 1598/18 test box to ECM wiring harness. - Check wire for open circuit between test box socket 38 and 3-pin connector terminal 3, according to wiring diagram. Wire resistance: Max. 1.5 Checking activation - Disconnect harness connector for fuel injectors 1 and 4, and remove fuse 18. - Connect VAG 1527B voltage tester to connector terminals 2 and 3 using adapter cables from VW 1594 and VW 1594/15 adapter. - Operate starter and check ignition signal from Motronic ECM. LED must flicker - Switch ignition off. If LED does not flicker:
Page 25 of 25 28-22 - Connect VAG 1598/18 test box to ECM wiring harness. - Check wire for open circuit between test box socket 8 and 3-pin connector terminal 2, according to wiring diagram. Wire resistance: Max. 1.5 - Additionally check wires for short to one another. Specification: (no continuity) If no wiring malfunction is detected and voltage was present between terminals 1 and 3: - Replace Motronic ECM J220 page 24-9, item 16. If the voltage supply and activation is OK: - Re-connect 3-pin connector and high-voltage cable to coil. - Connect VAG 1527B voltage tester to coil terminals 1 and 15. WARNING! During the test, DO NOT touch the ignition coil terminals or the highvoltage cables. - Operate starter. LED must flicker - If necessary replace ignition coil power output stage N157.