24-1
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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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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24-3
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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24-6
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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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 -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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24-8
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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24-11
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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24-15
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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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-
37
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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with plastic or paper. DO NOT cover with
rags.
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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-
25
RPM cut-
off
5800 to 6000 RPM
Additional testing and adjusting values
repair
instructions
1)
Observe test conditions
page 24-22
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2)
Display fluctuates
3)
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
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
Repair
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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)
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
1 2 3 4
Indicated on display
Continue test only when:
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Motronic Multiport Fuel Injection (MFI) system, component locations
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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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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
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
5
1 2 3 4
Indicated on display
- Read duty cycle in display field 3 and write down.
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24-26
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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24-27
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
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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- Read Oxygen Sensor factor in display field 3.
Specified value: display fluctuates
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24-28
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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24-29
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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24-30
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
01
- 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-
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
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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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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- Press button.
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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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If NO:
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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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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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
Стр. 53 из 63
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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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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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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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Note:
When installing injectors, make sure the O-rings are not damaged.
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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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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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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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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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Read measuring value block
1 2 3 4
- Read Engine Idle Speed (RPM) in display field 1.
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- 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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