2.5l - Ignition/glow Plug System - Engine Code(s): Bpr & Bps (hatchback) Volkswagen New Beetle A4 рестайлинг

SAFETY PRECAUTIONS

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

1. Do not touch or disconnect the ignition coils with power output stages when the engine is running or turning at starting RPM.
2. Only disconnect and reconnect wires for the injection and ignition system, including test leads, if the ignition is turned off.

If special testing equipment is required during a 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. For trouble free operation of the electrical components a voltage of at least 11.5 volts is necessary.
2. It is possible that the control module will recognize a malfunction and store a Diagnostic Trouble Code (DTC) during some tests. After completing all tests and repairs, the DTC memory should therefore be checked and erased if necessary. Refer to «ENGINE CONTROL MODULE DTC MEMORY, CHECKING AND ERASING»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback__engine-control-module-dtc-memory-checking) .
3. If the engine only starts briefly and then shuts off again after troubleshooting, repairs or checking of components, it may be that the immobilizer is blocking the Engine Control Module (ECM). The ECM may have to be adapted then. Refer to Vehicle diagnosis, testing and information system "Guided Functions".

Scheme 1

1. Harness Connector for Knock Sensor (KS) 2 -G66- Gray Contacts are gold plated. Installed location (Scheme 2)
2. Harness Connector for Knock Sensor (KS) 1 -G61- Green Contacts are gold plated. Installed location (Scheme 2)
3. Knock Sensor (KS) 2 -G66- Note the installed position: wire connection points 45° toward the right on the outside.
4. Knock Sensor (KS) 1 -G61- Note the installed position: wire connection points downward vertically.
5. Bolt, 20 Nm Tightening specification affects function of the KS.
6. Ignition Coil with Power Output Stage -N70, N127, N291, N292, N323- Removal and installation, refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(/volkswagen/new-beetle/a4-2005-2011/remont/ignition-system/#25l-ignitionglow-plug-system-engine-codes-bpr-bps-hatchback__ignition-coils-with-power-output-stages).
7. Spark Plug, 25 Nm Type and electrode gap, refer to «TEST DATA AND SPARK PLUGS»(/volkswagen/new-beetle/a4-2005-2011/remont/ignition-system/#25l-ignitionglow-plug-system-engine-codes-bpr-bps-hatchback__test-data-and-spark-plugs). Remove and install using spark plug removal tool 3122B.
8. Bolt, 10 Nm
9. Camshaft Position (CMP) Sensor -G40- Contacts are gold plated.
10. O-ring Replace if damaged

Scheme 2

1. Green for KS 1
2. Gray for KS 2

TEST DATA AND SPARK PLUGS

FASTENER TIGHTENING SPECIFICATIONS

IGNITION COILS WITH POWER OUTPUT STAGES

Special tools and workshop equipment required

1. Ignition coil puller T40039

Removing

Remove the engine cover.

Disconnect the harness connector from the Secondary Air Injection (AIR) solenoid valve -N112- -arrow-.

Scheme 3

In order to prevent damage to the wire guide, remove the ignition coils with power output stage as follows

Using T40039, pull all ignition coils only approximately 10 millimeters (mm) out of the spark plug holes, starting with ignition coil -1-.

Scheme 4

Then, pull out all ignition coils a further 10 mm in the same sequence.

Disengage all connectors and pull them out only slightly.

After that, pull off all connectors -A-, starting at ignition coil -1-, and remove the ignition coils from the spark plug holes.

Scheme 5

Installing

Insert all ignition coils loosely into the spark plug holes.

Align the ignition coils to the recesses in the cylinder head cover and connect all connectors in reverse order of removal onto the ignition coils.

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

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 6

1. Ignition coil puller T40039

See also:
• ENGINE CONTROL MODULE DTC MEMORY, CHECKING AND ERASING
• IGNITION COILS WITH POWER OUTPUT STAGES
• TEST DATA AND SPARK PLUGS