28-1
Motronic Multiport Fuel
Injection (MFI) and ignition
system
Ignition system components
Notes:
Only components which specifically relate to
the ignition system are dealt with here. For
other components of the fuel injection and
ignition system
Repair Group 24.
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
Page 01-13
.
Safety precautions
Page 28-5
Technical data, spark plugs
Page 28-7
28-2
Ignition system, servicing
Note:
Engine Control Module (ECM) -J220-* with connector
Page 24-9
, item 12 .
1 - Ignition wires
Check for continuity
2 - Suppressor
0.6-1.4 k
3 - Terminal 1
4 - Terminal 15
5 - Ignition coil power output stage -N157-*
Checking
Page 28-31
6 - 10 Nm (7 ft lb)
7 - Ignition coil -N152-
Checking
Page 28-30
8 - Connector
3-pin
9 - Ground (GND) strap
28-3
10 - Knock Sensor (KS) 1 -G61-*
11 - 20 Nm (15 ft lb)
Tightening torque influences function of knock
sensor
12 - Spark plug connector
Use 3277 when disconnecting and connecting
4-6 k
13 - Spark plug
30 Nm (22 ft lb)
Remove and install with 3122B
Type and electrode gap
Page 28-7
14 - 25 Nm (18 ft lb)
15 - Clamp
16 - O-ring
Replace if damaged
17 - Camshaft Position (CMP) sensor -G40-*
Installing
Page 28-8
Checking camshaft position sensor
Page 28-22
28-4
18 - Dust cap
19 - Rotor arm
Marking: R1
0.6-1.4 k
20 - Distributor cap
Check for cracks and signs of tracking
Check contact wear
Clean before installing
Check carbon brush for wear and freedom of
movement
21 - Screening cap
28-5
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.
28-6
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.
28-7
Technical data, spark plugs
Engine code
ABA
Ignition timing
1)
Checking
Page 28-14
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
28-8
Distributor, removing and installing
Special tools, testers and auxiliary items
Pin wrench Matra V159
VAG 1331 torque wrench (5-50 Nm)
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.
28-9
Engine removed
- Set vibration damper (V-belt pulley) to TDC no. 1 cylinder.
Mark on camshaft sprocket must align with arrow on cylinder head cover.
28-10
Removing and installing distributor
Test conditions
Work sequence
Mark on distributor must align with mark on rotor arm or camshaft position
sensor cover.
Crankshaft and camshaft in no. 1 cylinder TDC position
- Remove distributor.
- Before installing the distributor, align oil pump shaft drive tongue parallel to
crankshaft.
28-11
Note:
When installing, turn rotor arm slightly right of the distributor marking. When
inserting, rotor arm will turn back to the marking.
- Install distributor. The pins on the distributor must point toward mounting bolt
threaded hole (arrow).
If not able to align markings:
Mark on distributor must align with mark on rotor arm or camshaft position
sensor cover.
- Tighten distributor mounting bolt.
Tightening torque: 25 Nm (18 ft lb)
- Loosen belt tensioner and take toothed drive belt off camshaft sprocket.
28-12
- Turn intermediate shaft sprocket with toothed drive belt in direction shown
(arrow), until rotor arm aligns with markings for no. 1 cylinder on distributor
housing (toothed drive belt slides over crankshaft sprocket).
Note:
For easier installation of the toothed drive belt, loosen belt tensioner lock nut only
approx. one thread.
Mark on distributor must align with mark on rotor arm or camshaft position
sensor cover.
- Place toothed drive belt on belt tensioner and camshaft sprocket.
28-13
- To tighten toothed drive belt, turn tensioner with pin wrench (e.g. Matra V159) in
direction shown (arrow).
Drive belt is correctly tensioned if it can be turned 90 with the thumb and
forefinger halfway between camshaft and intermediate shaft sprockets.
- Tighten tensioner lock nut.
Tightening torque: 45 Nm (33 ft lb)
- Rotate crankshaft two full turns and check adjustment.
- Check distributor housing and rotor arm markings.
- Install upper toothed belt protective cover.
- Before installing, clean distributor cap and check for cracks and signs of carbon
tracking, replace if necessary.
28-14
Ignition timing, checking
Special tools, testers and auxiliary items
VAG 1551/1552 scan tool with VAG 1551/3
adapter cable
Test conditions
Electrical consumers turned off (radiator
coolant fan must not run during the check)
Air conditioner turned off
Test sequence
- Connect VAG 1551 scan tool (VAG 1552) and
select "Engine Electronics" address word 01
Page 01-7
. When doing this the engine must be
running at idle speed.
Rapid data transfer
HELP
Select function XX
Indicated on display
- Press buttons -0- and -8- to select "Read Measuring Value Block" function 08
and press -Q- button to confirm input.
Read Measuring Value Block
HELP
Indicated on display
Input display group number XXX
- Press buttons -0-, -1- and -0- to input display group 010 and press -Q- button to
confirm input.
Read Measuring Value Block
10
1
2
3
4
Indicated on display (1-4
Display fields)
- Check measured values for ignition (display fields 3 and 4).
28-15
Display fields
1
2
3
4
Display group 010: Ignition 1
Display
xxx RPM
xx.x ms
xx.x
xx.x
Indicated
Engine speed Engine load Ignition angle (mapped value)
Ignition angle
Working
range
800 - 6000
RPM
0.0 - 25.0
ms
0.0 - 50.0
BTDC
0.0 - 40.0
BTDC
Specification
800 - 880
RPM
1.5 - 2.5 ms
11.0 - 13.0
BTDC
Max. 2.0
deviation from display field 3
-
-
Test conditions:
If the specification is not attained
page 24-71
, checking throttle valve
control module
Intake manifold temperature max. 50 C (122 F)
- Read the readiness code
Page 01-32
. If DTC
memory has been erased, verify repair via
appropriate display group
Page 01-34
,
Readiness code, creating.
- Press
button.
- Press buttons -0- and -6- to select "End Output"
function 06 and press -Q- button to confirm
input.
28-16
Misfire detection, checking
Special tools, testers and auxiliary items
VAG 1551/1552 scan tool with VAG 1551/3
adapter cable
Test sequence
- Connect VAG 1551 scan tool (VAG 1552) and
select "Engine Electronics" address word 01
Page 01-7
. When doing this the engine must be
running at idle speed.
Rapid data transfer
HELP
Select function XX
Indicated on display
- Press buttons -0- and -8- to select "Read measuring value block" function 08 and
press -Q- button to confirm input.
Read Measuring Value Block
HELP
Input display group number XXX
Indicated on display
- Press buttons -1-, -1- and -0- to input display group 110 and press -Q- button to
confirm input.
Read Measuring Value Block 110
1
2
3
4
Indicated on display (1-4
Display fields)
- Check the specifications for misfire detection (display fields 2-4).
28-17
Display fields
1
2
3
4
Display group 110: Misfire detection 1
Display
x.xx ms
xxx
xxx
xxxxxxxx
Indicated
Engine
load
Misfiring adversely affecting
exhaust gas (total)
Misfiring adversely affecting three way
catalytic converter (total)
Misfiring recognition
status
Working
range
0.00 - 25.00
ms
-
-
-
Specification
1.00 - 3.00
ms
0
0
00000000
-
If the specification is not attained
Page 28-18
, evaluating display group 110
- Read the readiness code
Page 01-32
. If DTC
memory has been erased, verify repair via
appropriate display group
Page 01-34
,
Readiness code, creating.
- Press
button.
- Press buttons -0- and -6- for the "End Output"
function and press -Q- button to confirm input.
28-18
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
Page 28-30
- Checking components of ignition system
Page 28-1
Fuel injector faulty
Fuel shortage
- Check fuel injectors
Page 24-119
- Check quantity of fuel in tank
28-19
Ignition timing control, checking
Special tools, testers and auxiliary items
VAG 1551/1552 scan tool with VAG 1551/3
adapter cable
Test conditions
Electrical consumers turned off (radiator
coolant fan must not run during the check)
Air conditioner turned off
Engine oil temperature at least 80 C (176
F)
Test sequence
- Connect VAG 1551 scan tool (VAG 1552) and
select "Engine Electronics" address word 01
Page 01-7
. When doing this the engine must be
running at idle speed.
Rapid data transfer
HELP
Select function XX
Indicated on display
- Press buttons -0- and -8- to select "Read Measuring Value Block" function 08
and press -Q- button to confirm input.
Read Measuring Value Block
HELP
Input display group number XXX
Indicated on display
- Press buttons -0-, -1- and -0- to input display group 010 and press -Q- button to
confirm input.
28-20
Read Measuring Value Block
10
1
2
3
4
Indicated on display (1-4
Display fields)
- Check the measured values for ignition timing control (display fields 1-4).
Display fields
1
2
3
4
Display group 010: Ignition 1
Display
xxx RPM
xx.x ms
xx.x
xx.x
Indicated
Engine speed
Engine load
Ignition angle (mapped
value)
Ignition angle
Working range 800 - 6000 RPM
0.0 - 25.0
ms
0.0 - 40.0
BTDC
0.0 - 40.0
BTDC
Specification
800 - 880 RPM
1.9 - 2.1 ms
11.0 - 13.0
BTDC
Max. 2.0
deviation from display field
3
2480 - 2520
RPM
1.7 - 1.9 ms
23.0 - 25.0
BTDC
Max. 2.0
deviation from display field
3
-
-
Test condition:
If the specification is not attained
Page 28-21
, continuation
Intake manifold temperature max. 50 C (122 F)
28-21
Continuation
- Check engine operating conditions
Page 24-
63
- Check throttle valve control module
Page 24-
71
- Check knock sensor and knock control
Page
28-25
If the specification is again not attained:
- Replace Engine Control Module (ECM) -J220-
Page 24-9
, item 12 .
- Read the readiness code
Page 01-32
. If DTC
memory has been erased, repair must be
verified via appropriate display group
Page
01-34
, Readiness code, creating.
28-22
Camshaft Position (CMP) sensor,
checking
Special tools, testers and auxiliary items
VAG 1598/18 test box
Multimeter (Fluke 83 or equivalent)
Connector test kit VW 1594
Wiring diagram
Test sequence
- Disconnect 3-pin connector from camshaft position sensor.
- Connect multimeter using test leads from VW 1594 to measure voltage at
terminals 1 and 3 of connector.
- Turn on ignition.
- Measure voltage between terminals 1 and 3.
Specification: 9-14.5 volts
- Turn off ignition.
28-23
If the specification is not attained:
- Connect VAG 1598/18 test box to Engine Control Module (ECM) wiring harness.
- Check wiring between test box and 3-pin connector for open circuit using wiring
diagram.
Terminal 1 and test box socket 56
Terminal 2 and test box socket 44
Resistance: max. 1.5 ohms (
)
- Check wire between 3-pin connector and relay panel -G1/4- for open circuit
using wiring diagram.
Terminal 3 and relay panel -G1/4-
Resistance: max. 1.5 ohms (
)
28-24
- Additionally check all wires for short circuit to
each other.
Terminal 3 and test box socket 44
Terminal 3 and test box socket 56
Terminal 2 and test box socket 56
Specification:
ohms (
)
If no wiring malfunction is detected and voltage
was present between terminals 1 and 3:
- Replace distributor with camshaft position
sensor
Page 28-3
, Item 17 .
If no wiring malfunction is detected and no
voltage was present between terminals 1 and 3:
- Replace Engine Control Module (ECM) -J220-
Page 24-9
, item 12 .
-
Read the readiness code
Page 01-32
. If DTC
memory has been erased, verify repair via
appropriate display group
Page 01-34
,
Readiness code, creating.
28-25
Knock Sensor (KS) and knock control,
checking
Special tools, testers and auxiliary items
VAG 1551/1552 scan tool with VAG 1551/3
adapter cable
VAG 1598/18 test box
Multimeter (Fluke 83 or equivalent)
Connector test kit VW 1594
Wiring diagram
Test sequence
- Connect VAG 1551 scan tool (VAG 1552) and
select "Engine Electronics" address word 01
Page 01-7
. When doing this the engine must be
running at idle speed.
Rapid data transfer
HELP
Select function XX
Indicated on display
- Press buttons -0- and -8- to select "Read Measuring Value Block" function 08
and press -Q- button to confirm input.
Read Measuring Value Block
HELP
Input display group number XXX
Indicated on display
- Press buttons -0-, -4- and -5- to input display group 045 and press -Q- button to
confirm input.
Read Measuring Value Block
45
1
2
3
4
Indicated on display (1-4
Display fields)
28-26
Note:
The check must be carried out during a test drive
as knock control is not active with an engine load
exceeding 3 ms.
- Perform test drive and observe specification for
knock control on display (second technician
necessary).
Display fields
1
2
3
4
Display group 045: Knock control
Display
xx.xx
xx.xx
xx.xx
xx.xx
Indicated
Ignition angle correction
cylinder 1
Ignition angle correction
cylinder 2
Ignition angle correction
cylinder 3
Ignition angle correction
cylinder 4
Working
range
0.0 - 15.0
0.0 - 15.0
0.0 - 15.0
0.0 - 15.0
Specification
0.0 - 12.0
0.0 - 12.0
0.0 - 12.0
0.0 - 12.0
If the specification is not attained
page 28-27
, evaluating display group 045
-
Read the readiness code
page 01-32
. If DTC
memory has been erased, verify repair via
appropriate display group
Page 01-34
,
Readiness code, creating.
- Press
button.
- Press buttons -0- and -6- to select "End Output"
function 06 and press -Q- button to confirm
input.
28-27
Evaluating display group 045
Display group: 045
Display fields: 1-4
Possible malfunction cause
Malfunction
elimination
All cylinders more than 12
Knock sensor faulty
- Continuation
Page 28-28
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
- Continuation
Page 28-28
Engine damage
Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine
Code(s): ABA, Repair Group 13
- Check compression pressures:
Attached components on
engine loose
- Tighten attached components
28-28
Continuation
If the specification is attained:
- Disconnect blue 3-pin connector -2- from Knock Sensor (KS) 1 -G61- -1-.
- 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
ohms (
)
- Connect VAG 1598/18 test box to ECM wiring harness.
28-29
If no wiring malfunction is detected:
If the malfunction is still present (malfunction again in Diagnostic Trouble Code
(DTC) memory):
- 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 (
)
- 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:
ohms (
)
- Loosen knock sensor and tighten again to 20 Nm (15 ft lb).
- Replace Knock Sensor (KS) 1 -G61-
Page 28-3
, item 10 .
-
Read the readiness code
Page 01-32
. If DTC memory has been erased,
verify repair via appropriate display group
Page 01-34
, Readiness code,
creating.
28-30
Ignition coil, checking
Special tools, testers and auxiliary items
Multimeter (Fluke 83 or equivalent)
Connector test kit VW 1594
Test sequence
- Disconnect connector and ignition wire from
ignition coil -N152-.
- Connect multimeter with test leads from VW
1594 to measure resistance.
If the specifications are not attained:
- Check ignition coil primary resistance with multimeter (Fluke 83 or equivalent)
between terminals 1 and 15.
Specification: 0.5-1.2 ohms (
)
- Check ignition coil secondary resistance with multimeter between terminals 4
and 15.
Specification: 3-4 k
- Replace ignition coil -N152-
Page 28-2
, item 7 .
28-31
Ignition coil power output stage,
checking
Special tools, testers and auxiliary items
VAG 1598/18 test box
Multimeter (Fluke 83 or equivalent)
VAG 1527B voltage tester
Connector test kit VW 1594
Wiring diagram
Checking voltage supply
- Disconnect 3-pin connector from ignition coil.
- Connect multimeter using test leads from VW 1594 to measure voltage at
terminals 1 and 3 of connector.
- Turn on ignition.
- Measure voltage between terminals 1 and 3.
If the specification is not attained:
Specification: 9-14.5 volts
- Turn off ignition.
28-32
- Check wire between 3-pin connector contact 1
and Ground for open circuit according to wiring
diagram.
Wire resistance: Max. 1.5 ohms (
)
- Check wire between 3-pin connector contact 3
and relay plate for open circuit according to
wiring diagram.
Resistance: max. 1.5 ohms (
)
If no wiring malfunction is detected and voltage
was present between terminals 1 and 3:
- Replace ignition coil -N152-
Page 28-2
, item
7 .
If no wiring malfunction is detected and no
voltage was present between terminals 1 and 3:
- Replace Engine Control Module (ECM) -J220-
Page 24-9
, item 12 .
- Read the readiness code
page 01-32
. If DTC
memory has been erased, verify repair via
appropriate display group
Page 01-34
,
Readiness code, creating.
Checking activation
- Disconnect the engine harness center connector
Page 24-2
, item 11 .
- Connect VAG 1527B voltage tester with test leads from VW 1594 and adapters
VW 1594/15 to terminals 2 and 3 of the connector.
28-33
- Operate starter and check ignition signal from
ECM.
LED must flicker
- Turn off ignition.
If the LED does not flicker:
If no wiring malfunction is detected and voltage was present between terminals 1
and 3:
- Connect VAG 1598/18 test box to ECM wiring harness.
- Check wiring between 3-pin connector and test box for open circuit according to
wiring diagram.
Terminal 2 and test box socket 8
Resistance: max. 1.5 ohms (
)
- Additionally check the wiring for short circuit to each other.
Terminal 1 and test box socket 8
Terminal 3 and test box socket 8
Specification:
ohms (
)
- Replace ECM -J220-
Page 24-9
, item 12 .
- Read the readiness code
Page 01-32
. If DTC memory has been erased,
verify repair via appropriate display group
Page 01-34
, Readiness code,
creating.
28-34
If the voltage supply and activation is OK.:
- Reconnect 3-pin harness connector and ignition
wire to ignition coil.
CAUTION!
During the following test do not touch the terminals of the ignition coil or test
cables.
- Connect LED voltage tester with test leads to terminals 1 and 15 on ignition coil.
- Operate starter.
The LED must flicker
- If necessary, replace ignition coil power output stage.