Ignition system components
Note. Only components which specifically relate to the ignition system are dealt with here. For other components of the fuel injection and ignition system, see MULTIPORT FUEL INJECTION (MFI) - 2.0L, ABA . The fuel injection and ignition system Engine Control Module (ECM) is equipped with On Board Diagnostic (OBD). Components marked with an asterisk (*) are checked via the On Board Diagnostic (OBD) program. Check Diagnostic Trouble Code (DTC) memory before carrying out repairs and troubleshooting. See CHECK DTC MEMORY (SCAN TOOL FUNCTION 02) .
Safety precautions. See SAFETY PRECAUTIONS .
Technical data, spark plugs. See TECHNICAL DATA, SPARK PLUGS .
Ignition system, servicing
Note. Engine Control Module (ECM) -J220- * with connector. See FUEL INJECTION SYSTEM, COMPONENTS .
Note. The following list refers to items in (Scheme 267).
- Ignition wires Check for continuity
- Suppressor 0.6-1.4 k ohm
- Terminal 1
- Terminal 15
- Ignition coil power output stage -N157-* Checking, See «IGNITION COIL POWER OUTPUT STAGE, CHECKING»(ref-203894-S13677645562005110800000)
- 10 Nm (7 ft lb)
- Ignition coil -N152- Checking, See «IGNITION COIL, CHECKING»(ref-203894-S42816168382005110800000)
- Connector 3-pin
- Ground (GND) strap
- Knock Sensor (KS) 1 -G61-*
- 20 Nm (15 ft lb) Tightening torque influences function of knock sensor
- Spark plug connector Use 3277 when disconnecting and connecting 4-6 k ohm
- Spark plug 30 Nm (22 ft lb) Remove and install with 3122B Type and electrode gap, See «TECHNICAL DATA, SPARK PLUGS»(ref-203894-S20365180942005110800000)
- 25 Nm (18 ft lb)
- Clamp
- O-ring Replace if damaged
- Camshaft Position (CMP) sensor -G40-* Installing, See «DISTRIBUTOR, REMOVING AND INSTALLING»(ref-203894-S30204833042005110800000) Checking camshaft position sensor, See «CAMSHAFT POSITION (CMP) SENSOR, CHECKING»(ref-203894-S14854788552005110800000)
- Dust cap
- Rotor arm Marking: R1 0.6-1.4 k ohm
- Distributor cap Check for cracks and signs of tracking Check contact wear Clean before installing Check carbon brush for wear and freedom of movement
- Screening cap
Identifying Components Of Ignition System. Scheme 267
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. After the work is completed, erase Diagnostic Trouble Code (DTC) memory. |
| 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. |
Technical data, spark plugs
| Engine code | ABA |
|---|---|
| Ignition timing (1) Checking | See IGNITION TIMING, CHECKING |
| Firing order | 1-3-4-2 |
| Spark plugs : VW/Audi | 101 000 044 AA |
| Manufacturer's designation | FR 8 DS |
| Electrode gap | 0.8 mm (0.032) (2) |
| Tightening torque | 30 Nm (22 ft lb) |
| (1) Not adjustable (2) Gap between Ground (GND) electrode and center electrode insulation | |
| (1) | Not adjustable |
| (2) | Gap between Ground (GND) electrode and center electrode insulation |
SPARK PLUG TECHNICAL DATA
Procedure
Note. The Engine Control Module (ECM) 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.
Checking no. 1 cylinder TDC markings
- Set flywheel -A- or drive plate -B- to TDC no. 1 cylinder.
Setting Flywheel Or Drive Plate To TDC No. 1 Cylinder. Scheme 268
Engine removed
- Set vibration damper (V -belt pulley) to TDC no. 1 cylinder.
Setting Vibration Damper (V -Belt Pulley) To TDC No. 1 Cylinder. Scheme 269
Scheme 270
- Mark on camshaft sprocket must align with arrow on cylinder head cover. (Scheme 270): Aligning Crankshaft Sprocket And Cylinder Head Cover Mark
- Mark on distributor must align with mark on rotor arm or camshaft position sensor cover.
Aligning Distributor Mark With Rotor Arm Or Camshaft Position Sensor Cover Mark. Scheme 271
Evaluating display group 110
| Display group: 110 | ||
|---|---|---|
| Display field: 2 + 3 | Possible malfunction cause | Malfunction elimination |
| More than 25 | Ignition coil faulty Ignition wire faulty Spark plug faulty | Check ignition coil See IGNITION COIL, CHECKING Checking components of ignition system, see MOTRONIC MULTIPORT FUEL INJECTION (MFI) AND IGNITION SYSTEM |
| Fuel injector faulty Fuel shortage | Check fuel injectors. See MULTIPORT FUEL INJECTION (MFI) - 2.0L, ABA . Check quantity of fuel in tank | |
EVALUATING DISPLAY GROUP 110
Continuation
- Check engine operating conditions. See «ENGINE OPERATION, CHECKING»(ref-203893-S21929035742005110800000) .
- Check throttle valve control module. See «THROTTLE VALVE CONTROL MODULE, CHECKING»(ref-203893-S41675259892005110800000) .
- Check knock sensor and knock control. See «KNOCK SENSOR (KS) AND KNOCK CONTROL, CHECKING»(ref-203894-S10888082632005110800000) .
If the specification is again not attained
- Replace Engine Control Module (ECM) -J220-. See «COMPONENT LOCATIONS, OVERVIEW»(ref-203893-S17623055512005110800000) .
- Read the readiness code. See «READINESS CODE, READING (SCAN TOOL FUNCTION 15»(ref-203892-S38778616292005110800000) ). If DTC memory has been erased, verify repair via appropriate display group. See «READINESS CODE, CREATING»(ref-203892-S31097275142005110800000) .
Evaluating display group 045
| Display group: 045 | ||
|---|---|---|
| Display fields: 1-4 | Possible malfunction cause | Malfunction elimination |
| All cylinders more than 12 Degrees | Knock sensor faulty | See CONTINUATION . |
| Connector corroded | ||
| Knock sensor incorrectly tightened | Loosen knock sensor and tighten to 20 Nm (15 ft lb) | |
| Attached components on engine loose | Tighten attached components | |
| Poor fuel quality | Change fuel type | |
| One cylinder deviates greatly from the others | Connector corroded | See CONTINUATION |
| Engine damage | Check compression pressures: See COMPRESSION PRESSURE, CHECKING . | |
| Attached components on engine loose | Tighten attached components | |
EVALUATING DISPLAY GROUP 045
Scheme 272
Scheme 273
- Disconnect blue 3-pin connector -2- from Knock Sensor (KS) 1 -G61- -1-. (Scheme 272): Identifying 3-Pin Connector And Knock Sensor
- Connect multimeter with test leads from VW 1594 to measure resistance between terminals 1 and 2, 1 and 3, and 2 and 3 on knock sensor connector. Specification INFINITE ohms ( ohm ) If the specification is attained
- Connect VAG 1598/18 test box to ECM wiring harness. (Scheme 273): Connecting VAG 1598/18 Test Box To ECM Wiring Harness
Scheme 274
- 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 Resistance: max. 1.5 ohms ( ohm ) (Scheme 274): Identifying Connector Terminals Of 3-Pin Knock Sensor Connector
- 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: INFINITE ohms ( ohm ) If no wiring malfunction is detected
- Loosen knock sensor and tighten again to 20 Nm (15 ft lb). If the malfunction is still present (malfunction again in Diagnostic Trouble Code (DTC) memory)
- Replace Knock Sensor (KS) 1 -G61-. (Scheme 267), item 10.
- Read the readiness code. See «READINESS CODE, READING (SCAN TOOL FUNCTION 15»(ref-203892-S38778616292005110800000) ). If DTC memory has been erased, verify repair via appropriate display group. See «READINESS CODE, CREATING»(ref-203892-S31097275142005110800000).