GENERAL NOTES ON IGNITION SYSTEM
For all Ignition/Glow plug system component locations. Refer to Ignition System Components Assembly Overview
For all Ignition/Glow plug system removal/installation procedures and torque specifications. Refer to REMOVAL AND INSTALLATION
Note. All manufacturers special tools as well as common tools may contain a manufacturer specific part number. These tools may be substituted with an equivalent aftermarket tool or are available for purchase through VW. Manufacturers special tools as well as common tools that contain a manufacturer specific part number may be referenced in the test procedure illustrations showing the tool use or installation. If the manufacturer specific tool is not being used, an equivalent aftermarket tool may be installed in the same manner as the manufacturers special tool. The manufacturers test box Test Box 121 Pin VAG 1598/31 is available for purchase or rental.
SAFETY PRECAUTIONS
| WARNING | Observe the following for all installations, especially in the 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. Test equipment must always be secured to the rear seat and operated by a second person. Test and measuring equipment that is operated from the passenger seat, the person seated could be injured in the event of an accident involving deployment of the passenger-side airbag. 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, if the ignition is turned off. |
| WARNING | The use of nails, paper clips, or another unauthorized materials to back-probe electrical harness connectors is strictly prohibited and may cause damage to the electrical harness connectors, terminal ends or damage to a component. Use only the manufacturers test lead kit or an equivalent aftermarket test lead kit for back-probing all electrical harness connectors. |
If engine is to be cranked at starting RPM without starting, e.g. for a compression test
Remove Fuse 6 (on fuse panel B) SB6 and Fuse 29 (on fuse panel B) SB29 from the fuse holder, E-box, plenum chamber.
By removing Fuse 6 (on fuse panel B) SB6, voltage supply of Ignition Coils with Power Output Stage -N70, N127, N291, N292- is interrupted, that of Fuel Injectors -N30, N31, N32, N33- by removing Fuse 29 (on fuse panel B) SB29.
TEST DATA, SPARK PLUGS
| Engine code | APH, AWP, AWV (1.8L / 110 kW 5V-Turbo engine) | |
|---|---|---|
| Engine Control Module (ECM) System identification | Motronic ME 7.5 | |
| Engine idle speed | 640 to 800 RPM (not adjustable) | |
| Engine speed (RPM) limitation | Starting at approx. 6500 RPM | |
| Ignition sequence | 1-3-4-2 | |
| Ignition timing | Not adjustable, regulated by Electronic control module | |
| Ignition system | Single coil ignition system with 6 ignition coils (output stages integrated) that are connected directly to spark plugs by the ignition cables. | |
| Spark plugs | 101 000 063 | |
| Manufacturer code | PFR 6 Q | |
| Spark plug gap | 1.0 to 1.1 mm | |
| Tightening torque | 25 Nm | |
CAMSHAFT POSITION SENSOR G40, CHECKING
Note. Use only gold-plated terminals when servicing terminals in harness connector of Camshaft Position (CMP) Sensor -G40-.
Special tools and workshop equipment required
- Multimeter.
- Wiring diagram.
Test requirements
- The Motronic Engine Control Module (ECM) - J220- fuses OK.
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
- Ignition switched off.
Test procedure
Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK
Procedure
Disconnect the Camshaft Position (CMP) Sensor -G40- electrical harness connector -1-.
Scheme 24
Switch the ignition on.
Using a Multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector terminals 1 to 3 for voltage.
Scheme 25
Specified value: about 5.0 V
Switch the ignition off.
If the specification was not obtained
Checking wiring
If the manufacturers test box is being used. Perform the following step.
Install the test box.
If the manufacturers test box is not being used. Perform the following step.
Remove the Motronic Engine Control Module (ECM) -J220-. Refer to MOTRONIC ENGINE CONTROL MODULE J220, REPLACING .
Using a Multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector to the Motronic Engine Control Module (ECM) electrical harness connector T121 for an open circuit.
| Camshaft Position (CMP) Sensor -G40- electrical harness connector terminals | Motronic Engine Control Module (ECM) electrical harness connector T121 terminals or test box sockets |
|---|---|
| 1 | 98 |
| 2 | 86 |
| 3 | Ground (GND) |
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
If necessary, repair the faulty wiring connection.
If no malfunction is found in the wiring and voltage supply was OK
Replace the Camshaft Position (CMP) Sensor -G40-.
If no malfunction is found in the wiring and voltage supply was not OK
Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY
Perform a road test to verify repair.
If the DTC does not return
Repair complete, Generate readiness code. Refer to READINESS CODE .
End diagnosis.
If the DTC does return and no malfunction is detected in the wiring and the voltage supply was OK
Replace the Motronic Engine Control Module (ECM) -J220-. Refer to MOTRONIC ENGINE CONTROL MODULE J220, REPLACING .
Assembly is performed in the reverse of the removal.
Final procedures
After the repair work, the following work steps must be performed in the following sequence
- Check the DTC memory «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback__diagnostic-mode-03-read-dtc) .
- If necessary, erase the DTC memory «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback__diagnostic-mode-04-erase-dtc) .
- If the DTC memory was erased, generate readiness code «READINESS CODE»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback) .
End of diagnosis.
CAMSHAFT ADJUSTMENT VALVE 1 N205, CHECKING
Special tools and workshop equipment required
- Multimeter.
- Wiring diagram.
Test requirements
- The Camshaft Adjustment Valve 1 -N205- fuse OK.
- Fuel Pump (FP) Relay -J17- OK, checking. Refer to the appropriate SYSTEM WIRING DIAGRAMS information.
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
- Ignition switched off.
Test procedure
Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK
Procedure
Remove the engine cover with air filter.
Disconnect Camshaft Adjustment Valve 1 -N205- electrical harness connector.
Using a Multimeter, check the Camshaft Adjustment Valve 1 -N205- for resistance.
Scheme 26
Specified value: 10.0 to 18.0 ohms (at approx. 20° C)
If the specified value was not obtained
Replace the Camshaft Adjustment Valve 1 -N205-.
If the specified value was obtained
Checking voltage
Switch the ignition on.
Using a Multimeter, Check the Camshaft Adjustment Valve 1 -N205- electrical harness connector terminal 1 to ground (GND) for voltage.
Scheme 27
Switch the ignition off.
Specified value: battery voltage.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
If necessary, repair the faulty wiring connection.
If the specified value was obtained
Checking wiring
If the manufacturers test box is being used. Perform the following step.
Install the test box.
If the manufacturers test box is not being used. Perform the following step.
Remove the Motronic Engine Control Module (ECM) -J220-. Refer to MOTRONIC ENGINE CONTROL MODULE J220, REPLACING .
Using a Multimeter, Check the Camshaft Adjustment Valve 1 -N205- electrical harness connector terminal 2 to the Motronic Engine Control Module (ECM) electrical harness connector T121 terminal 115 for an open circuit.
| Camshaft Adjustment Valve 1 -N205- electrical harness connector terminal | Motronic Engine Control Module (ECM) electrical harness connector T121 terminal or test box socket |
|---|---|
| 2 | 115 |
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
If necessary, repair the faulty wiring connection.
Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY
Perform a road test to verify repair.
If the DTC does not return
Repair complete, Generate readiness code. Refer to READINESS CODE .
End diagnosis.
If the DTC does return and no malfunction is detected in the wiring and the voltage supply was OK
Replace the Motronic Engine Control Module (ECM) -J220-. Refer to MOTRONIC ENGINE CONTROL MODULE J220, REPLACING .
Install the engine cover with air filter.
Final procedures
After the repair work, the following work steps must be performed in the following sequence
- Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback__diagnostic-mode-03-read-dtc) .
- If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback__diagnostic-mode-04-erase-dtc) .
- If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback) .
End of diagnosis.
KNOCK SENSORS G61 AND G66, CHECKING
The following procedure is used to diagnose all Knock Sensors --.
Special tools and workshop equipment required
- Multimeter.
- Wiring diagram.
Test requirements
- The mounting bolt of Knock Sensor (KS) 1 -G61- /Knock Sensor (KS) 2 -G66- tightened to 20 Nm.
- The Motronic Engine Control Module (ECM) - J220- fuses OK.
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
- Ignition switched off.
Test procedure
Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK
Procedure
Note. Before disconnecting the Knock Sensor -- electrical harness connectors, mark the component location.
Disconnect the Knock Sensor (KS) 1 -G61- electrical harness connector -1- or Knock Sensor (KS) 2 -G66- electrical harness connector -2-.
(APH Only)
Scheme 28
(AWP, AWV Only)
Scheme 29
Checking internal resistance
Using a Multimeter, check the Knock Sensor -- terminals 1 to 2 for an internal short.
Scheme 30
Specified value: infinity (Infinity).
If the specified value was not obtained
Replace the faulty Knock Sensor (KS) 1 -G61- /Knock Sensor (KS) 2 -G66-.
If the specified value was obtained
Checking wiring
If the manufacturers test box is being used. Perform the following step.
Install the test box.
If the manufacturers test box is not being used. Perform the following step.
Remove the Motronic Engine Control Module (ECM) -J220-. Refer to MOTRONIC ENGINE CONTROL MODULE J220, REPLACING .
Using a Multimeter, Check the Knock Sensor -- electrical harness connector to the Motronic Engine Control Module (ECM) J220 electrical harness connector T121 for an open circuit.
(APH Only)
Scheme 31
(AWP, AWV Only)
Scheme 32
| Knock Sensor (KS) 1 -G61- electrical harness connector terminals | Motronic Engine Control Module (ECM) electrical harness connector T121 terminals or test box sockets |
|---|---|
| 1 | 106 |
| 2 | 99 |
| Knock Sensor (KS) 2 -G66- electrical harness connector terminals | Motronic Engine Control Module (ECM) electrical harness connector T121 terminals or test box sockets |
|---|---|
| 1 | 107 |
| 2 | 99 |
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
If necessary, repair the faulty wiring connection.
If no malfunction is found in the wiring and the resistance was not OK
Replace the faulty Knock Sensor (KS) 1 -G61- /Knock Sensor (KS) 2 -G66-.
Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY
Perform a road test to verify repair.
If the DTC does not return
Repair complete, Generate readiness code. Refer to READINESS CODE .
End diagnosis.
If the DTC does return and no malfunction is detected in the wiring and the voltage supply was OK
Replace the Motronic Engine Control Module (ECM) -J220-. Refer to MOTRONIC ENGINE CONTROL MODULE J220, REPLACING .
Assembly is performed in the reverse of the removal.
Install the engine cover with air filter.
Final procedures
After the repair work, the following work steps must be performed in the following sequence
- Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback__diagnostic-mode-03-read-dtc) .
- If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback__diagnostic-mode-04-erase-dtc) .
- If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback) .
End of diagnosis.
IGNITION COILS WITH POWER OUTPUT STAGE N70, N127, N291, N292, CHECKING
The following procedure is used to diagnose all Ignition Coils with Power Output Stage --.
Special tools and workshop equipment required
- Multimeter.
- Diode test lamp.
- Wiring diagram.
Test requirements
- The Ignition Coils with Power Output Stage - N70, N127, N291, N292- fuses OK.
- TheFuel Pump (FP) Relay -J17- OK.
- The Engine Speed (RPM) Sensor -G28- OK, «ENGINE SPEED SENSOR G28, CHECKING»(/volkswagen/new-beetle/a4-1997-2005/remont/fuel-system/#18l-multiport-fuel-injection-engine-codes-aph-awp-awv-hatchback__engine-speed-sensor-g28-checking) .
- The Camshaft Position (CMP) Sensor -G40- OK, «CAMSHAFT POSITION SENSOR G40, CHECKING»(/volkswagen/new-beetle/a4-1997-2005/remont/ignition-system/#18l-ignitionglow-plug-system-engine-codes-aph-awp-awv-hatchback__camshaft-position-sensor-g40-checking) .
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
- Ignition switched off.
Test procedure
Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK
Procedure
Remove the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness screws.
Disconnect theIgnition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness connectors from the Ignition Coils with Power Output Stage -N70, N127, N291, N292-.
(APH Only)
Scheme 33
(AWP, AVW Only)
Scheme 34
Checking voltage supply
Switch the ignition on.
Using a Multimeter, check the Ignition Coil -- electrical harness connector terminals 1 to 4 for voltage.
Scheme 35
Specified value: battery voltage.
Switch the ignition off.
If the specified value was not obtained
Check the Ignition Coil -- electrical harness connector terminal 1 to the Fuel Pump (FP) Relay -J17- terminal 19/15 for an open circuit.
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
If necessary, repair the faulty wiring connection.
If the specified values were obtained
Checking activation
| WARNING | Do not touch the Ignition Coils -- connecting parts or adapter cables during the following test. |
Disable the power supply to theFuel Injectors -N30, N31, N32, N33- by removing Fuse (on fuse panel) -S229-.
Using a diode test lamp, check the Ignition Coil -- electrical harness connector terminals 1 to 3 for voltage.
Operate the starter.
The LED should flicker.
Switch the ignition off.
If the LED flickers and the voltage was OK
Replace the faulty Ignition Coils with Power Output Stage -N70, N127, N291, N292-.
If the LED does not flicker
Checking wiring
If the manufacturers test box is being used. Perform the following step.
Install the test box.
If the manufacturers test box is not being used. Perform the following step.
Remove the Motronic Engine Control Module (ECM) -J220-. Refer to MOTRONIC ENGINE CONTROL MODULE J220, REPLACING .
Using a Multimeter, Check the Ignition Coil -- electrical harness connector to the Motronic Engine Control Module (ECM) J220 electrical harness connector T121 for an open circuit.
| Ignition Coils with Power Output Stage -N70, N127, N291, 292- electrical harness connector terminal | Motronic Engine Control Module (ECM) electrical harness connector T121 terminal or test box socket |
|---|---|
| N70/3 | 102 |
| N127/3 | 95 |
| N291/3 | 103 |
| N292/3 | 94 |
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
If necessary, repair the faulty wiring connection.
If the specified values were obtained
Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY
Perform a road test to verify repair.
If the DTC does not return
Repair complete, Generate readiness code. Refer to READINESS CODE .
End diagnosis.
If the DTC does return and no malfunction is detected in the wiring and the voltage supply was OK
Replace the Motronic Engine Control Module (ECM) -J220-. Refer to MOTRONIC ENGINE CONTROL MODULE J220, REPLACING .
Assembly is performed in the reverse of the removal.
Connect the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness connectors to the Ignition Coils with Power Output Stage -N70, N127, N291, N292-.
Install the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness screws.
Final procedures
After the repair work, the following work steps must be performed in the following sequence
- Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback__diagnostic-mode-03-read-dtc) «PRELIMINARY CHECK»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback__preliminary-check) .
- If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback__diagnostic-mode-04-erase-dtc) .
- If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#18l-generic-scan-tool-engine-codes-aph-awp-awv-hatchback) .
End of diagnosis.
See also:
• Ignition System Components Assembly Overview
• REMOVAL AND INSTALLATION
• PRELIMINARY CHECK
• MOTRONIC ENGINE CONTROL MODULE J220, REPLACING
• DIAGNOSTIC MODE 04 - ERASE DTC MEMORY
• READINESS CODE
• DIAGNOSTIC MODE 03 - READ DTC MEMORY
• ENGINE SPEED SENSOR G28, CHECKING
• CAMSHAFT POSITION SENSOR G40, CHECKING