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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

Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical,

Engine Code(s): ABA, Repair Group 26

1 - EVAP Canister Purge Regulator Valve -N80-

2 - EGR Vacuum Regulator Solenoid Valve -N18-

3 - Mass Air Flow (MAF) sensor -G70-

4 - Throttle Position (TP) Sensor -G69-

5 - Engine Control Module (ECM) -J220-

6 - 4-pin harness connector

For Heated Oxygen Sensor (HO2S) -G39-

7 - Intake Air Temperature (IAT) sensor -G72-

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Motronic Multiport Fuel Injection (MFI) system, component locations

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Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical,

Engine Code(s): ABA, Repair Group 26

Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical,

Engine Code(s): ABA, Repair Group 26

Repair Group 28

8 - Idle Air Control (IAC) Valve (N71)

9 - EGR Temperature Sensor (G98)

10 - Exhaust Gas Recirculation (EGR) Valve

11 - CO tap tube

Where applicable

12 - Ignition coil

13 - Vehicle Speed Sensor (VSS) -G22-

Tested by On Board Diagnostic (OBD)

14 - Engine Coolant Temperature (ECT) sensor -G62-

With ECT Sensor -G2-

15 - 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 -G28-

19 - Ignition distributor

With Camshaft Position (CMP) sensor -G40-

page 28-3

20 - Fuel pressure measuring port

Where applicable

21 - Injectors (N30-N33)

22 - Knock Sensor (KS) 1 -G61-

page 28-2

23 - Ground connection

24 - Fuel pressure regulator

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Repair Manual, 2.0 Liter 4-Cyl. 2V Engine Mechanical,

Engine Code(s): ABA, Repair Group 20

25 - Thermal Vacuum Valve (TVV)

For intake air preheating

26 - EVAP canister

Below Air Cleaner (ACL)

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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

page 24-19

Rules for cleanliness

page 24-20

Technical data

page 24-21

On Board Diagnostic program and electrical

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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 -G70-

Checking

Electrical testing, Repair Group 01

3 - Vacuum hose

To EGR Vacuum Regulator Solenoid Valve -N18-

page 24-1

, item 2

4 - T-connector

5 - Vacuum hose

To Evaporative Emission (EVAP) Canister Purge

Regulator Valve -N80-

EVAP 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) -J220-

Location: 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 -G62-

Black, with ECT sensor -G2-

For Motronic MFI

Removing: relieve cooling system pressure if

necessary

Checking

page 24-34

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21 - Connector

4-pin

Blue wiring for cavity -1- and brown/yellow wire for

cavity for ECT Sensor -G62-

22 - 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 -G28-

29 - 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 -

J278-

Voltage supply, checking: with ignition switched ON,

check voltage across terminals -3- and -4-

Specification: approx. 0.5 V

Electrical testing,

Repair Group 01

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 -4-

4 - 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 -G72-

Checking

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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Motronic Multiport Fuel Injection (MFI) system, component locations

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24-16

Intake manifold, lower, disassembling/assembling

1 - Retaining clip

Check for proper fit

2 - Fuel pressure regulator

Checking with fuel pressure test port -6-

page 24-

Checking without fuel test port -6-

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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Motronic Multiport Fuel Injection (MFI) system, component locations

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24-17

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 -G70-

9 - 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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Technical data

Engine code

ABA

Idle speed, checking
1)

Idle speed
with A/C
off

with A/C
on

840

40 RPM

870

40 RPM

Oxygen
sensor
factor

1.00

0.25 2)

CO
content

0.3 to 1.2 vol %

Engine control module
(ECM) 3)

When replacing,
perform Idle Air
Control (IAC) Valve,
checking

page 24-

RPM cut-
off

5800 to 6000 RPM

Additional testing and adjusting values

repair

instructions

Observe test conditions

page 24-22

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Display fluctuates

Checking Motronic ECM coding

Repair

Group 01

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24-22

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

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

Repair

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Motronic Multiport Fuel Injection (MFI) system, component locations

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Group 01

No DTCs stored in DTC Memory

Repair

Group 01

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)

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

Input display group number XXX

Indicated on display

- Press buttons -0- and -1- to select display group number 1.

- Press -Q- button to confirm input.

System in basic setting

1 2 3 4

Indicated on display

Continue test only when:

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24-24

- 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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24-25

Idle Air Control (IAC) Valve, checking

No DTC stored in DTC Memory

Repair

Group 01

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 2 3 4

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

1 2 3 4

Indicated on display

- Read duty cycle in display field 3 and write down.

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Note:

Testing can only be repeated if DTC Memory is erased first.

- Disconnect connector -1- from Engine Coolant Temperature Sensor -2-.

Duty cycle must increase and fall back to previous value

- 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

1 2 3 4

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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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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If YES:

Control Module J220) and hold to Ground (GND).

Value in display field 3 must increase

- Replace Heated Oxygen Sensor (HO2S)

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

1 2 3 4

Indicated on display (1-4 = display fields)

- 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

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

page 24-

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24-32

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

1 2 3 4

Indicated on display (1-4 = display fields)

If numerical value does not rise uniformly:

- 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.

- Perform electrical testing, test step 20

Repair Group 01

If necessary replace Throttle Position (TP) Sensor (G69)

page 24-15

, item -

14- and

page 24-33

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24-33

Throttle Position (TP) Sensor, replacing

Remove two screws -4-.

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

- 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)

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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

1 2 3 4

Indicated on display (1-4 = display fields)

Note:

- Read coolant temperature value in display field 2.

Temperature value must increase uniformly without interruption

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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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

Repair

Group 01

- 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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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

1 2 3 4

Indicated on display (1-4 = display fields)

If temperature value does not change:

- 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

- Perform electrical testing, test step 24

Repair Group 01

- If necessary replace Intake Air Temperature Sensor (G72)

page 24-14

, item -

9-.

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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.

CAUTION!

Shut-off lever on tester must be closed. Lever must be at right angle to

- Unscrew cap screw from measuring port and connect VAG 1318 gauge with

VAG 1318/10 adapter.

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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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24-38

If NO:

- 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.

- 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.

- Replace Fuel Pressure Regulator

Repair Group 20

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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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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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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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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:

Replace
Fuel
Pressure
Regulator

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Repair Manual, 2.0

Liter 4-Cyl. 2V Engine
Mechanical, Engine
Code(s): ABA, Repair
Group 20

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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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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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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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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 -1-
closed

over 30 C (86 F)

warm air connection -
2- closed

between 20 and 30 C

between cold and
warm air connection

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24-46

Deceleration damper, checking

Vehicles with manual transmission

Special tools

Drill bit or wire gauge: 3 mm (0.118 in.)

diameter

Checking

Adjusting

- 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.)

- 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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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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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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