Transcript
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Motronic Multiport Fuel Injection (MFI) system, component locations
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Motronic Multiport Fuel Injection (MFI) system, component locations 1 - EVAP Canister Purge Regulator Valve -N80Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 20 2 - EGR Vacuum Regulator Solenoid Valve -N18Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 26 3 - Mass Air Flow (MAF) sensor -G704 - Throttle Position (TP) Sensor -G695 - Engine Control Module (ECM) -J2206 - 4-pin harness connector For Heated Oxygen Sensor (HO2S) -G397 - Intake Air Temperature (IAT) sensor -G72-
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8 - Idle Air Control (IAC) Valve (N71) 9 - EGR Temperature Sensor (G98) Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 26 10 - Exhaust Gas Recirculation (EGR) Valve Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 26 11 - CO tap tube Where applicable 12 - Ignition coil Repair Group 28 13 - Vehicle Speed Sensor (VSS) -G22Tested by On Board Diagnostic (OBD) 14 - Engine Coolant Temperature (ECT) sensor -G62With ECT Sensor -G215 - Central harness connector
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16 - 3-pin harness connector Color: blue For knock sensor (KS) 17 - 3-pin connector Color: white For engine speed sensor 18 - Engine speed (RPM) sensor -G2819 - Ignition distributor With Camshaft Position (CMP) sensor -G40page 28-3 20 - Fuel pressure measuring port Where applicable 21 - Injectors (N30-N33) 22 - Knock Sensor (KS) 1 -G61page 28-2 23 - Ground connection 24 - Fuel pressure regulator
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25 - Thermal Vacuum Valve (TVV) For intake air preheating 26 - EVAP canister Below Air Cleaner (ACL) Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 20
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Multiport Fuel Injection (MFI) system, checking - Perform Output Diagnostic Test Mode (DTM) using VAG 1551 Scan Tool (ST) Repair Group 01 - Check connections for air leaks (false air). All injectors must click If one or more injectors do not click: - See Fuel Injectors, checking,
page 24-43 .
If OK: - Substitute known good injectors for those that do not click. - Repeat Output DTM. If OK: - Replace injectors that did not click.
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Components marked with an asterisk (*) are checked by the On Board Diagnostic (OBD) program Repair Group 01 Components marked with a double asterisk (**) are checked during the Output Diagnostic Test Mode Repair Group 01 Hose connections are secured with screw-type or locking clamps. Replace all clamps with screw-type clamps At least 11.5 V is required for satisfactory function of electrical components CAUTION! Do not use sealing compounds that contain silicone. Traces of silicone particles entering the engine are not burned in the engine and can damage the oxygen sensor probe. Safety precautions Rules for cleanliness Technical data
page 24-19 page 24-20
page 24-21
On Board Diagnostic program and electrical
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testing of the Multiport Fuel Injection and ignition system Repair Group 01
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Air intake system, components 1 - Air Cleaner (ACL) Disassembling and assembling
page 24-17
Only disconnect or connect harness connector - 2 with ignition switched OFF 2 - Connector 4-pin Mass Air Flow (MAF) sensor -G70Checking
Electrical testing, Repair Group 01
3 - Vacuum hose To EGR Vacuum Regulator Solenoid Valve -N18page 24-1 , item 2 4 - T-connector 5 - Vacuum hose To Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80EVAP system Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 20
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6 - Intake air duct Screw part of hose clamp must not interfere with Throttle Position (TP) Sensor 7 - Pressure regulator valve for crankcase breather 8 - Intake manifold, upper Position with long screw First tighten to lower part, then fasten to brackets Disassembling and assembling
page 24-17
9 - 30 Nm (22 ft lb) Exhaust Gas Recirculation (EGR) system Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 26 10 - Connector hose 11 - Noise damper For Idle Air Control (IAC) system 12 - To A/C system 13 - Connector Disconnect and connect only with ignition switched OFF 14 - Mounting plate
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15 - 10 Nm (7 ft lb) 16 - Engine Control Module (ECM) -J220Location: plenum chamber, right side For MFI, Oxygen Sensor control, knock regulation, rpm governor, ignition and On Board Diagnostic Replacing: carry out Basic Settings (Closed Throttle Position test) page 24-22 17 - To vacuum brake booster 18 - Retaining clip: Check for proper fit 19 - O-ring Always replace 20 - Engine Coolant Temperature (ECT) sensor -G62Black, with ECT sensor -G2For Motronic MFI Removing: relieve cooling system pressure if necessary Checking
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21 - Connector 4-pin Blue wiring for cavity -1- and brown/yellow wire for cavity for ECT Sensor -G6222 - 20 Nm (15 ft lb) 23 - Support Between upper intake manifold and cylinder head 24 - Gasket Always replace 25 - Intake manifold, lower Disassembling and assembling
page 24-16
26 - Fuel supply line White arrow From Fuel Pump (FP) Module in fuel tank Secure with spring clamps
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27 - Fuel return line Blue arrow To fuel tank Secure with spring clamps 28 - Engine Speed (RPM) Sensor -G2829 - Support ring 30 - To crankcase 31 - Deflector
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32 - Hot air intake From hot air deflector plate on exhaust manifold Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 26 33 - Heated Oxygen Sensor (HO2S) 2 (G39) Tightening torque: 50 Nm (37 ft lb) Location: in three way Catalytic Converter (TWC) Lubricate threads with "G5"; G5 must NOT enter slots in probe body Voltage supply for heating circuit via HO2S Relay J278Voltage supply, checking: with ignition switched ON, check voltage across terminals -3- and -4Specification: approx. 0.5 V Repair Group 01
Electrical testing,
Check heater circuit continuity 34 - 4-pin harness connector For Heated Oxygen Sensor (HO2S) probe and heater Location: right rear engine mount 35 - Holding ring
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Intake manifold, upper, disassembling/assembling 1 - M6: 10 Nm (7 ft lb) M8: 20 Nm (15 ft lb) 2 - Bracket For wiring to EGR Valve 3 - Bracket For deceleration damper -44 - Deceleration damper Vehicle with manual transmission only Checking and adjusting
page 24-46
5 - Support bracket For accelerator Pedal cable Cable, adjusting Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 20 6 - Idle Air Control (IAC) Valve (N71)*/** Resistance: 7 to 10 Ohms Checking
page 24-25
7 - Noise damper For Idle Air Control (IAC) system
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8 - Support ring 9 - Intake Air Temperature (IAT) sensor -G72Checking
page 24-36
Tightening torque: 10 Nm (7 ft lb) 10 - Intake manifold, upper 11 - Gasket Always replace 12 - Throttle body If stop screw for throttle basic setting has been incorrectly adjusted, replace Throttle Body assembly
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13 - 3 Nm (27 in lb) 14 - Throttle position (TP) Sensor (G69) Checking
page 24-32
Replacing
page 24-33
3-pin connector is for MFI With ignition switched ON, check voltage supply at 3-pin connector terminals -1- and -3- Specification: approx. 5 V 4-pin connector is for Automatic Transmission Control Module (J217) If auto. trans. is replaced, perform basic adjustment Repair Manual, 4 Spd. Automatic Transmission 01M On Board Diagnostic (OBD), Repair Group 01 15 - O-ring Always replace Included with replacement throttle position sensor 14-
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Intake manifold, lower, disassembling/assembling 1 - Retaining clip Check for proper fit 2 - Fuel pressure regulator Checking with fuel pressure test port -637 Checking without fuel test port -6-
page 24-
page 24-40
3 - O-ring Replace if damaged 4 - Fuel Injectors (N30-N33) Checking
page 24-43
Resistance: 14 to 21.5 Ohms 5 - Intake manifold, lower 6 - Cap screw Test port for measuring fuel pressure Where applicable; not furnished on all vehicles Discontinued from 1995 m.y. 7 - 10 Nm (7 ft lb) 8 - Fuel rail
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Air Cleaner (ACL), disassembling/assembling 1 - Rubber grommet 2 - Filter insert 3 - Air cleaner upper section 4 - Thermal Vacuum Valve (TVV) For intake air preheating With metal or notch toward regulator flap Intake air preheating, checking
page 24-44
5 - Gasket Replace if damaged 6 - Fuse 7 - O-ring Always replace 8 - Mass Air Flow (MAF) Sensor -G709 - 10 Nm (7 ft lb)
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10 - Vacuum hose 11 - Vacuum reservoir 12 - Air cleaner lower section 13 - Support
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Safety rules WARNING! To avoid personal injury or damage to the injection and ignition system: DO NOT touch or disconnect ignition wires when cranking engine or when engine is running. Disconnect and connect wires of the ignition and injection system-even test leads-only with ignition switched OFF. When cranking engine without starting it (example: compression testing) disconnect Ignition Coil Power Output Stage (N157) and fuse 18 (S18).
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Rules for cleanliness CAUTION! First: Clean fuel connections before loosening. When fuel system is open: DO NOT use compressed air if you don't need it. Move vehicle only if you must. If you cannot finish repairs, carefully cover parts with plastic or paper. DO NOT cover with rags. Use clean parts only. DO NOT unwrap new parts before needed. Only use new parts, not loose or used parts from tool box.
Lay removed parts on clean surface. Cover
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with plastic or paper. DO NOT cover with rags.
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Technical data Engine code
ABA
Idle speed, checking 1) Idle speed 840 with A/C off 870
40 RPM 40 RPM
with A/C on Oxygen sensor factor
1.00
CO content
0.3 to 1.2 vol %
Engine control module (ECM) 3)
RPM cutoff
0.25 2)
When replacing, perform Idle Air Control (IAC) Valve, checking page 2425 5800 to 6000 RPM
Additional testing and adjusting values instructions 1)
Observe test conditions
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repair
page 24-22
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2)
Display fluctuates
3)
Checking Motronic ECM coding Group 01
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Repair
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Function 04, "Basic Setting," initiating Note: Ignition timing, idle speed and Oxygen Sensor factor (CO content) cannot be adjusted. Check these first: Engine oil temperature at least 80 C (176 F) Electrical consumers OFF (Coolant Fan must not run during test) A/C OFF Throttle cable adjustment OK Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 20
VAG 1551 Scan Tool (ST) connected
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Repair
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Group 01 No DTCs stored in DTC Memory Group 01
Repair
No leaks in exhaust system - Start engine and let run with closed throttle. 1) - Operate Scan Tool while observing display: - Press button -1- for "Rapid data transfer" operating mode. 1) 1)
These steps are only necessary if the ignition was switched off after checking and erasing the DTC Memory.
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- Press buttons -0- and -1- to enter address word 01 for "Engine Electronics". - Press -Q- button to confirm input. - Press
button.
- Press buttons -0- and -4- to select the "Basic Setting" function. - Press -Q- button to confirm input. Note: When the Basic Setting function is selected, the Motronic Engine Control Module adjusts the idle speed. The EVAP Canister Purge Regulator Valve (N80) is closed. Start basic Setting
HELP
Indicated on display
Input display group number XXX
- Press buttons -0- and -1- to select display group number 1. - Press -Q- button to confirm input. System in basic setting 1234
1
Indicated on display Continue test only when:
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Coolant temperature is over 80 C (176 F) (display field 2) Engine has run 2 minutes more at Closed Throttle Position
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- Read closed throttle speed in display field 1. Specified values: 840 40 RPM (A/C OFF) 870 40 RPM (A/C ON) - Read Oxygen Sensor factor in display field 3. Specified value: 1.00
0.25 fluctuating
- Read ignition timing in display field 4. Specified value: approx. 12
before TDC
- When Coolant Fan is not running, end Basic Setting function by pressing button. - Press buttons -0- and -6- to select the "End Output" function. - Press -Q- button to confirm input If specified values are not obtained: - Switch ignition off.
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- Check Accelerator Pedal for ease of operation. - Disconnect Motronic Engine Control Module connector and reconnect. - Check and if necessary adjust deceleration damper page 24-46 - Test drive car and check DTC Memory again. - Repeat engine Basic Setting.
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Idle Air Control (IAC) Valve, checking No DTC stored in DTC Memory Group 01
Repair
VAG 1551 Scan Tool (ST) connected with "Read Measuring Value Block" function (08) selected (display group number 1) Repair Group 01 Reading measuring value block
1
1234
Indicated on display Continue testing only when: Coolant temperature is over 80 C (176 F) - display field 2 Engine has run 2 minutes more at idle - Press -C- button. - Press buttons -0- and -5- to select display group number 5. - Press -Q- button to confirm input.
Reading measuring value block 1234
5
Indicated on display - Read duty cycle in display field 3 and write down.
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- Disconnect connector -1- from Engine Coolant Temperature Sensor -2-. Duty cycle must increase and fall back to previous value Note: Testing can only be repeated if DTC Memory is erased first. - Connect Engine Coolant Temperature Sensor. - Press
button.
- Press buttons -0- and -5- for "Erase DTC Memory" function. - Press -Q- confirm input. - Press
button.
- Press buttons -0- and -6- to select the "End Output" function. - Press -Q- to confirm input.
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Heated Oxygen Sensor (HO2S) and Oxygen Sensor control, checking Test using VAG 1551 Scan Tool (ST) with engine idling. Engine basic setting OK
page 24-22
Exhaust system not leaking between Three Way Catalytic Converter (TWC) and cylinder head Voltage supply for Heated Oxygen Sensor (HO2S) heater circuit OK Repair Group 01, Output Diagnostic Test Mode VAG 1551 Scan Tool (ST) connected with "Read Measuring Value Block" function (08) selected (display group number 1) Repair Group 01 Reading measuring value block 1234
1
Indicated on display (1-4 = display fields) Continue testing only when: Engine Coolant Temperature (ECT) is over 80_C (176 F) - display field 2 Engine has run 2 minutes at idle
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- Read Oxygen Sensor factor in display field 3. Specified value: display fluctuates
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If value in display field 3 does not fluctuate: - Briefly accelerate and repeat test. - Press
button.
- Press buttons -0- and -6- to select the "End Output" function. - Press -Q- to confirm input. If Oxygen Sensor factor 1.00 does not change even during acceleration: - Disconnect connector -1- from Engine Coolant Temperature Sensor -2-. - Press buttons -0- and -5- to select the "Erase DTC Memory" function. - Press -Q- to confirm input.
- Unplug connector for Heated Oxygen Sensor (HO2S). - Connect adapter lead from VW 1594 to cavity 4 (wiring to Motronic Engine
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Control Module J220) and hold to Ground (GND). Value in display field 3 must increase If YES: - Replace Heated Oxygen Sensor (HO2S)
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page 24-12 , item - 33-
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If NO: - Perform electrical testing
Repair Group 01
- If necessary replace Motronic Engine Control Module (ECM) (J220) page 24-9 , item -16-. - Connect Engine Coolant Temperature Sensor. - Press
button.
- Press buttons -0- and -5- buttons to select the "Erase DTC Memory" function. - Press -Q- to confirm input. - Press
button.
- Press buttons -0- and -6- to select the "End output" function. - Press -Q- to confirm input.
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Partially open throttle/acceleration/ Wide Open Throttle (WOT) enrichment and deceleration fuel shut-off, checking Test using VAG 1551 Scan Tool (ST) with engine idling. VAG 1551 Scan Tool (ST) connected with "Read Measuring Value Block" function (08) selected (display group number 4) Repair Group 01 Reading measuring value block 4
Indicated on display (1-4 = display fields)
1234
- Read display value in display field 4: Specified value at Closed Throttle Position (CTP): 00010 - Check partial load enrichment by pressing Accelerator Pedal down steadily. Specified value: 00100 - Check acceleration enrichment by quick accelerations (Engine Coolant Temperature (ECT) under 70 C (158 F)) Specified value: 1 as first digit of five-digit number (briefly) - Check Wide Open Throttle (WOT) enrichment by briefly flooring Accelerator Pedal.
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Specified value: 1 as second digit of five-digit number with wide open throttle (briefly) - Check deceleration fuel shut-off by briefly accelerating 3000 RPM. Specified value: 1 as fifth digit of five-digit number (briefly) with throttle closed and over 1200 RPM - Press
button.
- Press buttons -0- and -6- to select the "End Output" function. - Press -Q- to confirm input. If specified values are not obtained: - Check and erase DTC Memory 01
Repair Group
- Check Accelerator Pedal mechanism for ease of operation. -
Check and if necessary adjust deceleration
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damper
page 24-46 .
- Check Throttle Position (TP) Sensor 32 .
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Throttle Position (TP) Sensor, checking Test using VAG 1551 Scan Tool (ST) with ignition on and engine not running. VAG 1551 Scan Tool (ST) connected with "Read Measuring Value Block" function selected (display group number 3) Repair Group 01 Reading measuring value block 3
Indicated on display (1-4 = display fields)
1234
- Open throttle slowly and read angle display in display field 3. Numerical value must increase uniformly over entire range. - Press
button.
- Press -0- and -6- to select the "End Output" function. - Press -Q- to confirm input. If numerical value does not rise uniformly: - Perform electrical testing, test step 20
Repair Group 01
If necessary replace Throttle Position (TP) Sensor (G69) 14- and page 24-33 .
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page 24-15 , item -
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24-33
Throttle Position (TP) Sensor, replacing Remove two screws -4-. - Remove Throttle Position Sensor -1-. Throttle valve -3- in Closed Throttle Position (CTP) New O-ring -2- Install Throttle Position Sensor in reverse order of removal. Tightening torque (screws -4-): 3 Nm (27 in. lb) After installing the Throttle Position Sensor, the Motronic Engine Control Module must be returned to basic settings page 24-22 . Note: On vehicles with automatic transmission, the Transmission Control Module must also be returned to basic settings Repair Manual, 4 Spd. Automatic Transmission 01M On Board Diagnostic (OBD), Repair Group 01
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Стр. 43 из 63
24-34
Engine Coolant Temperature (ECT) Sensor, checking Test using VAG 1551 Scan Tool (ST) with engine idling. Engine cold VAG 1551 Scan Tool (ST) connected with "Read Measuring Value Block" function selected (display group number 1) Repair Group 01 Reading measuring value block 1
Indicated on display (1-4 = display fields)
1234
- Read coolant temperature value in display field 2. Temperature value must increase uniformly without interruption Note: If the temperature display increases in jumps of 2 to 5 C, this is caused by the Motronic ECM and not by a malfunctioning ECT Sensor. 77.7 C will be displayed if this temperature is reached or if there is an interruption (open circuit). If malfunctions and irregular engine running occur in certain temperature ranges, and the temperature value does not increase without interruption, then the temperature signal has been temporarily interrupted and the sensor must be replaced.
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Motronic Multiport Fuel Injection (MFI) system, component locations
- Press
button.
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Motronic Multiport Fuel Injection (MFI) system, component locations
24-35
- Press buttons -0- and -6- to select the "End Output" function. - Press -Q- to confirm input. If temperature value does not change: - Perform electrical testing, test step 17 Group 01
Repair
- If necessary replace Engine Coolant Temperature Sensor (G62) page 24-9 , item 20-. CAUTION! First reduce pressure in the cooling system.
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Стр. 46 из 63
Motronic Multiport Fuel Injection (MFI) system, component locations
24-36
Intake Air Temperature (IAT) Sensor, checking Test using VAG 1551 Scan Tool (ST) with closed throttle. Engine cold VAG 1551 Scan Tool (ST) connected with "Read Measuring Value Block" function selected (display group number 3) Repair Group 01 Reading measuring value block 3
Indicated on display (1-4 = display fields)
1234
- Read Intake Air Temperature value in display field 4. Temperature value must increase uniformly without interruption - Press
button.
- Press buttons -0- and -6- buttons to select the "End Output" function. - Press -Q- to confirm input If temperature value does not change: - Perform electrical testing, test step 24
Repair Group 01
- If necessary replace Intake Air Temperature Sensor (G72) 9-.
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page 24-14 , item -
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Стр. 47 из 63
Motronic Multiport Fuel Injection (MFI) system, component locations
24-37
Fuel Pressure Regulator and residual pressure, checking Vehicles with fuel pressure test port on fuel rail Fuel Pump delivery quantity OK, checking Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 20 WARNING! Fire hazard! To prevent fuel spray when loosening connecting points, place rags around respective connection. - Unscrew cap screw from measuring port and connect VAG 1318 gauge with VAG 1318/10 adapter. CAUTION! Shut-off lever on tester must be closed. Lever must be at right angle to
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Motronic Multiport Fuel Injection (MFI) system, component locations
Стр. 48 из 63
direction of flow -arrow-. - Start engine and let engine idle. - Measure fuel pressure. Specified value: approx. 2.5 bar (36 psi).
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Стр. 49 из 63
Motronic Multiport Fuel Injection (MFI) system, component locations
24-38
- Disconnect vacuum hose -1- from connector line -2-. Fuel pressure must increase: approx. 3.0 bar (43 psi) - Switch ignition OFF. - Check for leaks and residual pressure by watching for pressure drop on gauge. After 10 minutes, at least 2 bar (29 psi) pressure must still remain. If NO: - Start engine and let idle. - After pressure builds up, switch ignition off and simultaneously clamp return hose (hose has arrow pointing away from fuel rail). - Watch whether pressure drops on gauge. If NO: - Replace Fuel Pressure Regulator
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Repair Group 20
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Стр. 50 из 63
Motronic Multiport Fuel Injection (MFI) system, component locations
24-39
If pressure drops again: -
Check Fuel Pump check valve Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code (s): ABA, Repair Group 20
- Check fuel lines, O-rings on fuel rail and Fuel Injectors for leaks. WARNING! Before disconnecting pressure gauge, hold a container near the connection and reduce fuel pressure by opening the valve. Fire hazard!
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Стр. 51 из 63
Motronic Multiport Fuel Injection (MFI) system, component locations
24-40
Fuel Pressure Regulator and residual pressure, checking Vehicles without fuel pressure test port on fuel rail Fuel Pump delivery quantity OK, checking Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 20 WARNING! Fire hazard! To prevent fuel spray when loosening connecting points, place rags around respective connection. - Disconnect fuel supply line -1- from fuel rail. - Connect VAG 1318 gauge -3- to "T" adapter using VAG 1318/10 adapter. - Connect "T" adapter to fuel rail using short piece of hose -A-, and secure with hose clamps.
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Стр. 52 из 63
Note: Hose connection is on fuel rail, not on Fuel Pressure Regulator -2-. CAUTION! Shut-off lever on tester must be closed. Lever must be at right angle to direction of flow -arrow-. - Start engine and let engine idle.
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Motronic Multiport Fuel Injection (MFI) system, component locations
24-41
- Measure fuel pressure. Specified value: approx. 3 bar (43 psi). - Switch ignition OFF. - Check for leaks and residual pressure by watching for pressure drop on gauge. After 10 minutes, at least 2 bar (29 psi) pressure must still remain. If NO: - Start engine and let idle. - After pressure builds up, switch ignition off and simultaneously clamp return hose (hose has arrow pointing away from fuel rail). - Watch whether pressure drops on gauge. If NO: -
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Replace Fuel Pressure Regulator
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Стр. 54 из 63
Motronic Multiport Fuel Injection (MFI) system, component locations
Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA, Repair Group 20
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Стр. 55 из 63
Motronic Multiport Fuel Injection (MFI) system, component locations
24-42
If pressure drops again: -
Check Fuel Pump check valve Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code (s): ABA, Repair Group 20
- Check fuel lines, O-rings on fuel rail and Fuel Injectors for leaks. WARNING! Before disconnecting the gauge, hold a container near the connection and reduce fuel pressure by opening the pressure gauge valve. Fire hazard!
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Стр. 56 из 63
Motronic Multiport Fuel Injection (MFI) system, component locations
24-43
Fuel Injectors, checking Engine Speed (RPM) Sensor OK - Check triggering of Fuel Injectors Repair Group 01, Output Diagnostic Test Mode - Disconnect connector -1- from -2- Engine Coolant Temperature (ECT) Sensor (G62). - Adjust VAG 1630 digital potentiometer (side A set to 15 Ohm) and connect to G62 connector using adapter leads from VW 1594. - Remove upper part of intake manifold
page 24-13 .
- Remove fuel rail (fuel lines and Fuel Injectors remain connected).
- Install Fuel Injectors in VAG 1602 measuring device. - Disconnect connector from Ignition Coil (N152). - Operate Starter. Fuel Injectors must spray with uniform pulsing - Switch ignition off and check Fuel Injectors for leaks. Not more than 2 drops per minute
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Стр. 57 из 63
Note: When installing injectors, make sure the O-rings are not damaged.
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Стр. 58 из 63
24-44
Intake Air preheating, checking Control flap, checking No leaks in vacuum reservoir for control flap - Loosen Air Cleaner (ACL) upper section and remove filter element. - Turn Air Cleaner (ACL) upper part to expose control flap in Air Cleaner (ACL) lower section. - Disconnect vacuum hose of vacuum reservoir from Thermal Vacuum Valve (TVV). - Connect vacuum hose to VAG 1390 hand vacuum pump. - Operate pump and check for ease of movement of control flap and function of vacuum reservoir. Control flap must close cold air connection -1-
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Стр. 59 из 63
Motronic Multiport Fuel Injection (MFI) system, component locations
24-45
Thermal Vacuum Valve (TVV), checking - Connect vacuum hose to TVV. - Start engine and let idle. - Check position of control flap after max. 20 sec. Thermal Vacuum Valve (TVV) temperature
Position of control flap
under 20 C (68 F)
cold air connection -1closed
over 30 C (86 F)
warm air connection 2- closed
between 20
between cold and warm air connection
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and 30 C
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Motronic Multiport Fuel Injection (MFI) system, component locations
Стр. 60 из 63
24-46
Deceleration damper, checking Vehicles with manual transmission Special tools Drill bit or wire gauge: 3 mm (0.118 in.) diameter Checking - Open throttle valve and close again, until deceleration damper plunger -2- just touches roller -3-. - In this position, measure gap between limiting screw -arrow- and throttle valve lever -1- with gauge or drill bit. Specification: 2.5-3.5 mm (0.098-0.138 in.) Adjusting - Clamp 3 mm (0.118 in.) drill/gauge between limiting screw -arrow- and throttle valve lever -1-. - Adjust deceleration damper so that plunger -2- just touches roller -3-.
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Motronic Multiport Fuel Injection (MFI) system, component locations
Стр. 61 из 63
24-47
Air intake system, checking for leaks (false air) Check, using engine leak detector spray G 001 800 A1 or equivalent Note: If there are leaks, vacuum in the air intake system draws in the spray. The spray reduces the ignition point of the fuel/air mixture which reduces engine RPM and increases the CO reading. CAUTION! To prevent personal injury, observe manufacturer's instructions and cautions. Check using VAG 1551 Scan Tool (ST) and VAG 1363A CO tester (or equivalent) with engine idling. - Connect VAG 1551 Scan Tool (ST) with "Read Measuring Value Block" (08) function selected (display group number 1) Repair Group 01 - Press -Q- button to confirm input. Indicated on display (1-4 = display fields)
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Motronic Multiport Fuel Injection (MFI) system, component locations
Read measuring value block
Стр. 62 из 63
- Read Engine Idle Speed (RPM) in display field 1.
1234
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Стр. 63 из 63
Motronic Multiport Fuel Injection (MFI) system, component locations
24-48
- Connect VAG 1363A CO tester with VAG 1363/3 adapter cable to CO tap tube. - Start engine and let run at Closed Throttle Position (CTP). - Systematically spray parts of Intake Air system with commercially available leak detector spray. - If engine idle speed drops, or Oxygen Sensor factor changes (display field 3), check for leaks. - Repair any leaks found. - Press
button.
- Press buttons -0- and -6- to select the "End Output" function. - Press -Q- button to confirm input.
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