2.0L - Ignition/glow Plug System - Engine Code(s): Cbfa & Ccta (Sedan) (A5 Platform): Other Volkswagen Jetta V

SAFETY PRECAUTIONS

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following

Scheme 8

1. If engine is to be cranked at starting speed without starting, for example during a compression pressure test, disconnect the connectors from the ignition coils and the 8 pin connector for the fuel injectors -3-.
2. After performing the work, check and erase the Diagnostic Trouble Code (DTC) memory. Refer to "Guided Functions" in the vehicle diagnostic tester.
3. Do not touch or disconnect the ignition coils with power output stages when the engine is running or turning at starting speed.
4. Only disconnect and reconnect wires for the injection and ignition system, including test leads, when the ignition is turned off.
5. The battery must only be disconnected and connected with the ignition turned off, otherwise the Engine Control Module (ECM) can be damaged. Obtain the radio code for radios with a anti-theft code before disconnecting the battery.
6. Follow required safety precautions after connecting the battery. Refer to «Removal and Installation»(ref-479507-S12863980962012061300000) .

If special testing equipment is required during road test, note the following

1. Test and measuring instruments must be secured to the rear seat and operated by a second person from this location.

If test and measuring instruments are operated from the front passenger seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered.

IGNITION SYSTEM

1. The Engine Control Module (ECM) is equipped with On Board Diagnostic (OBD). Before repairs such as fault finding, check the Diagnostic Trouble Code (DTC) memory first. Refer to "Guided Function" in the vehicle diagnostic tester.
2. For trouble free operation of the electrical components a voltage of at least 12 volts is necessary.
3. To conclude work, check the DTC memory of the ECM, erase all DTC entries which may have occurred during the tests and repairs. If the DTC memory was erased, the readiness code must be generated again. Refer to "Guided Fault Finding" in the vehicle diagnostic tester.
4. If the engine only starts briefly and then shuts off again after troubleshooting, repair or checking of the components, it may be that the immobilizer is blocking the ECM. The control module may have to be adapted then, refer to "Guided Functions" in the vehicle diagnostic tester.

Scheme 9

1. Knock Sensor 1 -G61- On the front of the cylinder head under the intake manifold. Contacts are gold plated. For electrical connectors see scheme 5 Removing and installing, refer to «Knock Sensor 1 -G61»(ref-479526-S38434591842012061300000).
2. Bolt 22 Nm Tightening specification influences the function of the knock sensor.
3. Ignition Coil with Power Output Stage Ignition coil 1 with power output stage -N70-. Ignition coil 2 with power output stage -N127-. Ignition coil 3 with power output stage -N291-. Ignition coil 4 with power output stage -N292-. Removing and installing, refer to «IGNITION COIL WITH POWER OUTPUT STAGE»(ref-479526-S17068824852012061300000).
4. Spark Plug -- 25 Nm If the spark plug is replaced, lubricate the ignition coil with power output stage. Refer to «INSTALLING, IGNITION COILS WITH POWER OUTPUT STAGES»(ref-479526-S26752744142012061300000). Note the change intervals. Type and electrode gap, refer to «SPARK PLUG TECHNICAL DATA»(ref-479526-S25067257632012061300000). Remove and install using the spark plug removal tool 3122 B.
5. O-ring No replacement part available. Replace if damaged.
6. Engine Speed Sensor -G28- On the front lower left side of the cylinder block, next to the oil separator. (Scheme 11) Removing and installing, refer to «Engine Speed Sensor -G28»(ref-479526-S30689066282012061300000).
7. Bolt 9 Nm
8. Camshaft Position Sensor -G40- Bolted on the front of the cylinder head cover. (Scheme 10) For electrical connectors see scheme 5

Scheme 10

1. CMP sensor

Scheme 11

1. Engine speed sensor

1. CMP sensor
2. Knock sensor 1
3. 8 pin harness connector for fuel injectors

SPARK PLUG TECHNICAL DATA

IGNITION COIL WITH POWER OUTPUT STAGE

Special tools and workshop equipment required

1. Ignition Coil Puller T40039
2. Special Lubricant G 052 141 A2

Removing

Note. Follow all safety precautions. Refer to SAFETY PRECAUTIONS . Note the general information regarding the ignition system. Refer to IGNITION SYSTEM . Ignition system component overview, refer to IGNITION SYSTEM COMPONENT OVERVIEW . To pull off the spark plugs, please place the ignition coil puller T40039 on the topmost thick rib -arrow- of the of the ignition coils with power output stages. Lower ribs may be damaged if they are used.

Remove the engine cover. Refer to ENGINE COVER .

Pull all ignition coils approximately 30 mm out of spark plug shaft -arrow- using the ignition coil puller T40039.

Scheme 12

Disconnect the connectors -arrows- from the ignition coils with output stages.

Scheme 13

INSTALLING, IGNITION COILS WITH POWER OUTPUT STAGES

Note. The ignition coils with power output stages must be greased with special lubricant G 052 141 A2 when installing new spark plugs. This prevents the sealing hose on the ignition coil from sticking on the spark plug. The lubricating paste must spread onto the spark pug when installing the ignition coil. New ignition coils with power output stages are already greased when delivered.

Apply a thin bead of special lubricant G 052 141 A2 around the ignition coil sealing hose -arrow-. The bead must be 1 to 2 mm thick.

Scheme 14

Set all ignition coils loosely into the spark plug shaft.

Align the ignition coils to the connectors -arrows- and connect all connectors to ignition coils simultaneously.

Scheme 15

Press the ignition coils uniformly onto the spark plugs by hand.

KNOCK SENSOR 1 -G61

Removing

Disconnect the electrical connector -2- for the knock sensor.

Remove the coolant pump. Refer to COOLANT PUMP .

Note. The knock sensor is located below the intake manifold behind the coolant pump.

Remove the knock sensor.

Installing

Installation is carried out in the reverse order while noting the following

1. Tightening specification, refer to «IGNITION SYSTEM COMPONENT OVERVIEW»(ref-479526-S02200303142012061300000) .

ENGINE SPEED SENSOR -G28

Removing

Remove the engine cover. Refer to ENGINE COVER .

Open the charge air pipe hose clamp -2-.

Scheme 16

Disconnect the electrical connector -arrow-.

Remove the noise insulation. Refer to Description and Operation .

Remove the bolts -1 and 4- and remove the charge air pipe downward from the throttle valve control module -J338-.

Reposition the clamp -1- and remove the charge air pipe hose downward from the charge air cooler.

Scheme 17

Disconnect the electrical connector -1- from the engine speed sensor.

Remove the engine speed sensor bolt.

Installing

Installation is carried out in the reverse order while noting the following

1. Tightening specifications, refer to «IGNITION SYSTEM COMPONENT OVERVIEW»(ref-479526-S02200303142012061300000) .