b4 28 Ignition Servicing

Ignition, servicing Page 1 of 31
28-1
Ignition, servicing
General notes on ignition system
This section deals specifically with ignition-

related components. The other components of
the injection and ignition system Page 24-1 .
For the electric components to work properly, a

voltage of at least 11.5 V is required.
The battery must only be disconnected and

connected with the ignition switched off, since
the Engine Control Module (ECM) can
otherwise be damaged.
Engine Control Module (ECM) is equipped with

On Board Diagnostic (OBD).
Components marked with * are tested via On

Board Diagnostic (OBD) Page ST-22 ,
Diagnostic mode 3: Check DTC memory.
It is possible that the control module will

recognize a malfunction and store a DTC during
some tests. Therefore the following work steps
must be performed in the mentioned sequence
after ending all tests and repairs.
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 6/12/2004
28-2
- - Check DTC memory Page ST-22 ,

Diagnostic mode 3: Check DTC Memory,
- - Erase DTC memory Page ST-26 ,

Diagnostic mode 4: Reset/erase diagnostic
data
- - For completion, generate readiness code

Page ST-52 .
Removing and installing ignition components

Page 28-3 .
Safety precautions Page 28-7 .
Test data, spark plugs Page 28-9 .
28-3
Ignition
components,
removing and
installing
Note:
Motronic Engine
Control Module
(ECM) -J220-*
with harness
connector
Page 24-1 , item
4.
1 - Ignition
wire
Checking
for
continuity
2 - Suppressor
0.6 to 1.4
k
3 - Terminal 1
4 - Terminal
15
5 - Ignition
Coil Power
Output
Stage -
N157-*
Checking
Page
28-23
6 - 10 Nm
28-4
7 - Ignition
Coil -
N152-
Component
location
Page 24-2 ,
item no. 8
Checking
Page
28-23
8 - Connector
3-pin
Terminals
are gold-
plated
9 - Ground
(GND)
strap
10 - 11Knock
Sensor
(KS) 1 -
G61-*
Component
location
Page 24-4 ,
item no. 18
Contact
surfaces
between
knock
sensor
and
cylinder
block
must be
free of
corrosion,
dirt and
grease
Checking
Page
28-20
12 - 20 Nm
Tightening
torque
affects
function of
Knock
Sensor
(KS)
13 - Spark plug
connector
4 to 6
k
28-5
14 - Spark
plug, 30
Nm
Type and
spark
plug gap
Page
28-9 ,
test data,
spark
plugs
15 - 25 Nm
16 - Clamp
17 - O-ring
Replace
if
damaged
18 - Camshaft
Position
(CMP)
Sensor -
G40-*
Removing
and
installing
Page
28-10
Check
Camshaft
Position
(CMP)
Sensor -
G40-
Page 28-
16
19 - Dust seal
cap
20 - Rotor arm
Identification:
R1
0.6 to 1.4
k
28-6
21 - Distributor
cap
Check
for
cracks
and
signs of
tracking
Check
for
contact
wear
Clean
before
installing
Check
carbon
brush for
wear and
freedom
of
movement
22 - Protective
cap
28-7
Safety precautions
WARNING!
Observe the following for all installations,

especially in engine compartment due to lack
of room:
Route lines of all types (e.g. for fuel,

hydraulic, EVAP canister system, coolant
and refrigerant, brake fluid, vacuum) and
electrical wiring so that the original path is
followed.
Watch for sufficient clearance to all moving

or hot components.
Fuel system is under pressure! Before

opening system, place rags around the
connection point. Then release pressure by
carefully loosening connection.
If special testing equipment is required during

road test, note the following:
Test equipment must always be secured to the

rear seat and operated from there by a second
person.
28-8
If test and measuring equipment is operated

from the passenger seat, the person seated
there could be injured in the event of an accident
involving deployment of the passenger-side
airbag.
To reduce the risk of personal injury and/or

damage to the fuel injection and ignition system,
always observe the following:
Do not touch or disconnect ignition wires when

engine is running or turning at starting RPM.
Only disconnect and reconnect wires for

injection and ignition system, including test
leads, when ignition is switched off.
If engine is to be cranked at starting RPM

without starting:
- Disconnect 3-pin connector from ignition coil

Page 28-4 , item 8 .
- Remove fuse 18 from fuse holder.
Note:
By removing fuse 18, voltage supply to the fuel

injectors is interrupted.
28-9
Test Data, Spark Plugs
Engine Code ABA

Ignition sequence 1-3-4-2
Spark plugs
VW/Audi 101 000 044 AA
Manufacturer code FR 8 DS
Spark plug gap 0.8 mm1)
Tightening torque 30 Nm
Engine Control Module (ECM) 2)

System identification Motronic M5.9
Terminals at Engine Control Module (ECM) 68
Replacement part number See Parts Catalog
Engine speed (RPM) limitation starting at approx. 5800 RPM
1) Gap between Ground (GND) electrode and center electrode insulation
2) Replacing Engine Control Module (ECM) Page 24-105
28-10
Ignition distributor, removing and

installing
Note:
The Motronic control module requires the

no. 1 cylinder TDC signal from the
camshaft position sensor to orient the
fuel injection and knock sensor systems
as per firing order.
Recommended special tools and

equipment
V159 Pin wrench
V.A.G1331 Torque wrench (5 to 50

Nm)
28-11
Removing ignition distributor
Checking markings of TDC cylinder 1:
- Set flywheel -A- or drive plate -B- to

TDC cylinder 1.
Mark on camshaft sprocket must

align with (arrow) on cylinder head
cover.
28-12
Mark on distributor must align with

mark on rotor arm or camshaft
position sensor cover.
- Remove mounting bolt for clamp and
remove distributor.
Installing distributor
Requirement
Crankshaft and camshaft in TDC

position cylinder 1.
Procedure
- Before installing distributor align oil

pump shaft drive tongue parallel to
crankshaft.
28-13
- Install distributor. Pins on distributor

must point toward mounting bolt
threaded hole (arrow).
Note:
When installing, turn rotor arm slightly

right of the distributor marking. When
inserting, rotor arm will turn back to the
marking.

- Tighten distributor mounting bolt.
Tightening torque: 25 Nm
If not able to align markings:
- Loosen belt tensioner and take

toothed drive belt off camshaft
sprocket.
28-14
- Turn intermediate shaft sprocket with

toothed drive belt in direction shown
(arrow), until rotor arm aligns with
markings for no. 1 cylinder on
distributor housing (toothed drive belt
slides over crankshaft sprocket).

- Place toothed drive belt on belt
tensioner and camshaft sprocket.
Note:
For easier installation of the toothed

drive belt, loosen belt tensioner lock nut
only approx. one thread.
28-15
- To tighten toothed drive belt, turn

tensioner with pin wrench (e.g. Matra
V159) in direction shown (arrow).
Drive belt is correctly tensioned if it can

be turned 90 with thumb and
forefinger halfway between camshaft
and intermediate shaft sprockets.
- Tighten tensioner lock nut.

Tightening torque: 45 Nm
- Rotate crankshaft two full turns and
check adjustment.
- Check distributor housing and rotor
arm markings.
- Install upper toothed belt protective
cover.
- Before installing, clean distributor
cap and check for cracks and signs
of carbon tracking, replace if
necessary.
28-16
Camshaft Position (CMP) sensor,

checking

equipment
V.A.G1526 Multimeter
V.A.G1594 Connector test kit
V.A.G1527 Voltage test lamp
Test requirements
The respective fuses of Motronic

Engine Control Module (ECM) -
J220- must be OK:
Electrical Wiring Diagrams,
Troubleshooting & Component
Locations
Battery voltage must be at least
11.5 volts.
All electrical consumers such as
lights and rear window defroster
must be switched off.
Parking brake must be engaged or
else daylight driving lights will be
switched on.
For vehicles with automatic
transmission, selector lever must be
in -P-.
28-17
Ground (GND) connections between engine,

transmission, and chassis must be OK.
Ignition switched off.
Checking voltage supply
- Disconnect 3-pin connector for Camshaft

Position (CMP) Sensor -G40- on distributor.
- Connect multimeter to outer terminals of the

disconnected connector for Camshaft Position
(CMP) sensor for voltage measurement.
- Switch ignition on.
Specified value: at least 9.0 V
- Switch ignition off.
If there is no voltage:
- Check wires according to wiring diagram

Page 28-18 .
28-18
Checking wiring
- Connect test box to control module wiring

harness Page ST-11 , connect test box for
wiring test.
- Check wires between test box and 3-pin

connector to Engine Control Module (ECM) for
open circuit according to wiring diagram.
Terminal 1 + socket 56
Wire resistance: max. 1.5
- Check wire between 3-pin connector terminal 3
and relay carrier -G1/4- for open circuit
according to wiring diagram.
- Check wires for short circuit to each other.
Specified value:
28-19
If no malfunctions are found in the wires and

there was voltage between outer terminals:
- Replace distributor with Camshaft Position

(CMP) Sensor -G40- Page 28-10 , removing
and installing distributor.
- Erase DTC memory of Engine Control Module

(ECM) Page ST-26 , Diagnostic mode 4:
Reset/erase diagnostic data.
- Generate readiness code Page ST-52 .
If no malfunctions are found in the wires and

there was no voltage between outer terminals:
- Replace Motronic Engine Control Module (ECM)

-J220- Page 24-105 .
28-20
Knock sensors, checking
Note:
Contact surfaces between knock sensor and

cylinder block must be free of corrosion, dirt
and grease.
For the Knock Sensors to function properly, it is

important for tightening torque to be exactly 20
Nm.
Use only gold-plated terminals when servicing

terminals in harness connector of knock
sensors.
Recommended special tools and equipment
V.A.G1526 Multimeter or V.A.G1715

multimeter
Wiring diagram
28-21
Test requirements
Knock sensor securing bolt

tightened to 20 Nm.
Checking resistance
- Disconnect the 3-pin harness

connector -2- for Knock Sensor (KS)
1 -G61- (-1-).
- Measure resistance between
terminals 1 + 2, 1 + 3 and 2 + 3 on
connector to knock sensor.
Specified value:
If specified value is not obtained:
- Replace Knock Sensor (KS) 1 -G61-

Page 28-4 , item 10 .
- Erase DTC memory of Engine
Control Module (ECM) Page ST-
26 , Diagnostic mode 4: Reset/erase
diagnostic data.
- Generate readiness code Page
ST-52 .
If specified value is obtained:
- Check wires according to wiring

diagram Page 28-22 .
28-22
Checking wiring

wiring test.
- Check wires between test box and 3-pin

- Check wires for short circuit to each other.
Specified value:
If no malfunctions are detected in the wires and the

resistance values were OK:
- Replace Knock Sensor (KS) 1 -G61- Page

28-4 , item 10 .
28-23
Ignition coil, checking
Recommended special tools and equipment
Test sequence
- Disconnect 3-pin connector at ignition coil

- Disconnect 3-pin interference suppression

connector at ignition coil Page 28-3 , item 2 .
Checking resistances
- Measure primary resistance between terminals 1

+ 15.
Specified value: 0.5 to 1.2
- Measure secondary resistance between
terminals 4 + 15.
Specified value: 3.0 to 4.0 k
If specified values are not obtained:
- Remove ignition coil and Ignition Coil Power

Output Stage -N157- Page 28-3 , item 5 .
28-24
- Repeat test.
If specified values are not obtained again:
- Replace Ignition Coil -N152- Page 28-4 , item

7.

If specified values are obtained:
- Check ignition coil power output stage Page

28-25 .
28-25
End stage for ignition coil, checking

equipment
V.A.G1527 Voltage test lamp
Wiring diagram
28-26
Test requirements
The respective fuses of Ignition Coil

-N152- must be OK:
Electrical Wiring Diagrams,
Troubleshooting & Component
Locations
Battery voltage must be at least
11.5 volts.
Ground (GND) connections
between engine, transmission, and
chassis must be OK.
All electrical consumers such as
lights and rear window defroster
must be switched off.
Parking brake must be engaged or
else daylight driving lights will be
switched on.
For vehicles with automatic
transmission, selector lever must be
in -P-.
If vehicle is equipped with an A/C
system, it must be switched off.
Engine speed (RPM) sensor must
be OK, checking Page 24-61 .
Camshaft Position (CMP) sensor
must be OK, checking Page 28-
16 .
28-27
Test sequence
- Disconnect 3-pin connector from ignition coil

Checking voltage supply
- Measure voltage supply between terminals 1 + 3

of disconnected connector -4-.
- Switch ignition on.
Specified value: at least 11.5 V
- Switch ignition off.
If there is no voltage:

and Ground (GND) for open circuit according to
wiring diagram.
and relay carrier -G1/4- for open circuit
according to wiring diagram.
If there is no malfunction in voltage supply:
- Check activation Page 28-28 .
28-28
Checking activation
WARNING!
Do not touch ignition coil connecting

parts or adapter cables during the
following test.
- Remove fuse 18 from fuse holder.
- Connect diode test lamp to terminals

2 + 3.
- Operate starter and test ignition
signal from Engine Control Module
(ECM).
LED should flicker.
If LED flickers and voltage supply is

OK:
- Replace Ignition Coil Power Output

Stage -N157- Page 28-3 , item 5 .
28-29

If LED does not flicker:
- Check wires according to wiring diagram

Page 28-29 .
Checking wiring

wiring test.
- Check wire between test box and 3-pin

- Check wires for short circuit to B+ or Ground
(GND).
Specified value:
If no malfunctions are found in wires:
- Replace Motronic Engine Control Module (ECM)

-J220- Page 24-105 .

b4 28 Ignition Servicing

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Ignition, servicing Page 1 of 31

This section deals specifically with ignition-

For the electric components to work properly, a

The battery must only be disconnected and

Engine Control Module (ECM) is equipped with

Components marked with * are tested via On

It is possible that the control module will

- - Check DTC memory Page ST-22 ,

- - Erase DTC memory Page ST-26 ,

- - For completion, generate readiness code

Removing and installing ignition components

Safety precautions Page 28-7 .

Test data, spark plugs Page 28-9 .

Observe the following for all installations,

Route lines of all types (e.g. for fuel,

Watch for sufficient clearance to all moving

Fuel system is under pressure! Before

If special testing equipment is required during

Test equipment must always be secured to the

If test and measuring equipment is operated

To reduce the risk of personal injury and/or

Do not touch or disconnect ignition wires when

Only disconnect and reconnect wires for

If engine is to be cranked at starting RPM

- Disconnect 3-pin connector from ignition coil

- Remove fuse 18 from fuse holder.

By removing fuse 18, voltage supply to the fuel

Test Data, Spark Plugs

Engine Code ABA

Engine Control Module (ECM) 2)

1) Gap between Ground (GND) electrode and center electrode insulation

2) Replacing Engine Control Module (ECM) Page 24-105

Ignition distributor, removing and

The Motronic control module requires the

Recommended special tools and

V159 Pin wrench

V.A.G1331 Torque wrench (5 to 50

Removing ignition distributor

Checking markings of TDC cylinder 1:

- Set flywheel -A- or drive plate -B- to

Mark on camshaft sprocket must

Mark on distributor must align with

Crankshaft and camshaft in TDC

- Before installing distributor align oil

- Install distributor. Pins on distributor

When installing, turn rotor arm slightly

Mark on distributor must align with

If not able to align markings:

- Loosen belt tensioner and take

- Turn intermediate shaft sprocket with

Mark on distributor must align with

For easier installation of the toothed

- To tighten toothed drive belt, turn

Drive belt is correctly tensioned if it can

- Tighten tensioner lock nut.

Camshaft Position (CMP) sensor,

Recommended special tools and

V.A.G1594 Connector test kit

V.A.G1527 Voltage test lamp

The respective fuses of Motronic