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Edition 08.1997

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Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
1AV injection and ignition system

Repair Group
01 - Self-diagnosis
24 - Mixture preparation, Injection
28 - Ignition system

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Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2011 Volkswagen AG, Wolfsburg 00056406820

 1AV injection and ignition system - Edition 08.1997

Contents

01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Features of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Technical data of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.4 Connecting fault reader V.A.G 1551 and selecting engine control unit . . . . . . . . . . . . . . . .2
1.5 Connecting Vehicle Diagnosis, Testing and Information system VAS 5051 and selecting
engine electronics control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.6 Interrogating and erasing fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Volkswa
1.7 Fault table . . . . . . . . . . . . . . . . . . . . . . .s.w.ag. e.n.A.G.. . . . . . .g.en. A. G. d. o.e.s . . . . . . . . . . . . . . . . . . . . .8
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2 Final control diagnosis . . . . . . . .ed. b.y. . . . . . . . . . . . . . . . . . . . . . . . . .g.ua.ra. . . . . . . . . . . . . . . .12
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2.1 Final control diagnosis . . . . .th.o.r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .te.e o. . . . . . . . . . . . .12
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2.2 Performing final control diagnosis ss
a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . . . . . . . .12

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3 Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

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3.1 Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

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3.2 Read measured value block and basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

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3.3 Display group overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

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24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

spec
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1 Servicing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

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1.1 Servicing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.2 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.3 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

rrectne
1.4 Removing and installing parts of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
1.5 Dismantling and assembling fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

ss o
1.6 Dismantling and assembling intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
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1.7 Dismantling and assembling air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

form
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1.8 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

atio
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1.9 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

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1.10 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
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2 Check components and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

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2.1 Check components and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

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2.2 Checking Lambda probe and Lambda control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
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2.3 Checking Lambda probe heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
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2.4 Checking engine operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
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2.5 Checking throttle valve control part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
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2.6 Checking intake manifold pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
2.7 Checking coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
2.8 Checking intake air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
2.9 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
2.10 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2.11 Checking intake air system for leaks (unmetered air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
2.12 Checking intake air preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
2.13 Wire routing engine wiring loom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
3 Replacing and matching engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3.1 Replacing and matching engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3.2 Replacing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3.3 Performing basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
3.4 Matching engine control unit to electronic immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
3.5 Checking control unit voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
4 Checking additional signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
4.1 Checking additional signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
4.2 Testing speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Contents i
 1AV injection and ignition system - Edition 08.1997

4.3 Checking air conditioner and air conditioner compressor signals . . . . . . . . . . . . . . . . . . . .69

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

1 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
1.1 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
1.2 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
1.3 Removing and installing parts of the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
1.4 Dismantling and assembling distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
1.5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
1.6 Adjustment data, Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
1.7 Checking and adjusting ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
1.8 Checking Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
1.9 Checking ignition transformer and output stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
1.10 Checking knock sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

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ii Contents
 1AV injection and ignition system - Edition 08.1997

01 - Self-diagnosis

1 - Self-diagnosis
1.1 - Self-diagnosis

Note:

The self-diagnosis monitors only a part of the injection and ignition system. For fault finding the binder "Fault
finding engine" must also be used in every case.

1.2 - Features of self-diagnosis

The engine control unit (control unit for 1AV fuel injection and ignition system -J382) is equipped with a fault
memory.

If faults occur in the sensors and components being monitored, they will be stored in the fault memory together
with an indication of the type of fault.

Faults which only occur sporadically will have the addition "sporadic fault" on the print out. These faults will be
indicated on the display by the addition "/SP". The cause of sporadic faults can be e.g. a loose contact or a
brief open circuit. If a sporadic fault does not occur again within 40 engine starts, it will be erased from the fault
memory.

The faults stored can be read-out with the fault reader V.A.G 1551 or the vehicle system tester V.A.G 1552 =>
Page 6 .

The fault memory must be erased

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1.3 - Technical data of self-diagnosis

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◆ The data transfer between control unit and fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 is
carried out in the operating mode "Rapid data transfer".
◆ The fault memory is equipped with a non-volatile memory.
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Interrogating control unit versions

The control unit version is displayed when the fault reader V.A.G 1551 or the vehicle system tester V.A.G 1552
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Selectable functions when using the fault reader V.A.G 1551 or V.A.G 1552
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1.1 - Self-diagnosis 1
 1AV injection and ignition system - Edition 08.1997

Function Prerequisite
Engine station‐ Engine running
ary, ignition at idling speed
switched on
02 Interrogating yes yes
fault memory
03 Final control di‐ yes no
agnosis
04 Basic setting yes1) yes2)3)
05 Erasing fault yes yes
memory
06 Ending output yes yes
08 Read measured yes yes
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10 Adaption yes no

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1) Must be carried out after performing the following work:
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Replacing control unit, throttle valve control part or engine.
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2) Only possible when the coolant temperature is above 80 °C. Prior to this, this function is blocked.

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3) Must be carried out when checking and adjusting the ignition timing point.

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4) Currently is only used for checks in the factory.
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1.4 - Connecting fault reader V.A.G 1551 and selecting engine control unit
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Special tools, testers, measuring instruments and auxiliary items required

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◆ Fault reader V.A.G 1551

2 01 - Self-diagnosis
 1AV injection and ignition system - Edition 08.1997
◆ Cable V.A.G 1551/3

Note:

The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
is not possible.
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• Battery voltage at least 11 aV.
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• Fuse No. 21 must be OK.s s c

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• Earth connections on front of clutch housing and on cylinder head OK.
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- -> Fold driver's side stowage compartment down.
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- Connect fault reader V.A.G 1551 with cable V.A.G 1551/3.

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Start engine => Page 1 , Table "Selectable functions".
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Notes:

◆ If the display remains blank, check diagnostic connector voltage supply =>Fault finding programme in "Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations" binder
◆ If the display does not indicate as described in the work sequence:

=> Fault reader operating instructions

◆ If due to an input fault "Fault in the data transfer!" is displayed, pull wire off fault reader, reconnect and repeat
work step.

-> Indicated on display:

V.A.G - SELF DIAGNOSIS HELP
1 - Rapid data transfer*
2 - Flash code output*

* Appears alternately

- Operate fault reader taking into account the information on the display:
- Press key 1 for "Rapid data transfer".
- Press keys 0 and 1 for address word "Engine electronics" and confirm entry with Q key.

-> The fault reader V.A.G 1551 display will show the system designation and version.

1.4 - Connecting fault reader V.A.G 1551 and selecting engine control unit 3
 1AV injection and ignition system - Edition 08.1997
- Press the ⇒key.

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Further measures see repair procedures.

1.5 - Connecting Vehicle Diagnosis, Testing and Information system VAS 5051 and selecting
engine electronics control unit

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All the functions that were previously
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VAS 5051 in operating modeiseVehicle self-diagnosis:
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=> Operating instructions
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Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
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◆ -> VAS 5051 Vehicle diagnosis, Testing and Information system

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Test conditions
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• Fuse No. 21 must be OK.

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• The battery voltage must be at least 11.5 V.

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• Earth connection between engine (on gearbox bell housing) and body (below battery) OK.
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- Connect tester VAS 5051 with diagnosis cable VAS 5051/1 or VAS 5051/3 as follows:
Prote AG.

- -> Fold driver's side stowage compartment down.

- Fit diagnosis cable connector onto diagnosis connector.
- Depending upon desired function
switch ignition on
or

4 01 - Self-diagnosis
 1AV injection and ignition system - Edition 08.1997
start engine and run at idling speed. Selectable functions => Page 1 .

Note:

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◆ The display fields will be displayed from top to bottom in functions 04 - Basic settings or 08 - Read data

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=> Operating instructions for Vehicle Diagnosis, Testing and Information System VAS 5051.

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-> Indicated on display:

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Selecting operating mode:

- Press key 1 for "Rapid data transfer".

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-> Indicated on display:

Selecting vehicle system:

- Press "01 - Engine electronics" on display -arrow-.

1.5 - Connecting Vehicle Diagnosis, Testing and Information system VAS 5051 and

selecting engine electronics control unit 5

 1AV injection and ignition system - Edition 08.1997
-> The control unit identification and coding -arrow- is shown on display e.g.:

Note:

Replace control unit if the control version displayed does not correspond to the vehicle

=> Page 63 .

-> Indicated on display:

Selecting diagnosis function:

At this point all diagnosis functions are available.

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- Press desired function on display.
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1.6 - Interrogating and erasing fault memory

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◆ Fault reader V.A.G 1551 (or vehicle system tester V.A.G 1552) with cable V.A.G 1551/3
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Work sequence
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- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)
ss o
cial p

f i

Only when engine does not start:

nform
mer

atio

- Switch ignition on.

om

n
c

i
or

n thi

- Switch on fault reader printer with the print key. The warning lamp in key must light up.
te

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pr

cum

-> Indicated on display:

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fo

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t.
Rapid data transfer HELP yi Co
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Select function XX t. C rig
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- Operate fault reader taking into account the information on the display:
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- Press keys 0 and 2 for function "Interrogate fault memory" and confirm entry with Q key.
AG.

-> The number of faults stored or "No fault recognised!" will be shown on the display.
X Faults recognised!

6 01 - Self-diagnosis
 1AV injection and ignition system - Edition 08.1997
If one or more faults are stored:

The stored faults will be displayed and printed out one after the other.

-> After the stored faults have been printed out, the display will show:
Rapid data transfer HELP n AG. Volkswagen AG do
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- Press keys 0 and 5 for the function "Erase
auth fault memory" and confirm entry with Q key. or
ac
ss

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Note:

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If the ignition is switched off between "Interrogate fault memory" and "Erase fault memory" the fault memory
erm

ab
will not be erased.

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-> Indicated on display:
hole

spec
Rapid data transfer
es, in part or in w

Fault memory is erased!

t to the co
- Press the ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

rrectness of i
- Eliminate the printed out faults using the appropriate fault table.
=> Page 8 .
l purpos

During test and assembly work faults can be recognised from other control units like e.g. plug disconnected.

nf
ercia

Therefore on completion the fault memories of all control units must be interrogated and erased. To do this:

orm
m

atio
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- Press key 0 twice for address word "Automatic test sequence" and confirm entry with Q key. The V.A.G
o

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c

1551 transmits all known address words one after the other.
or

thi
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When a control unit answers with its identification the number of stored faults appears on the display or "No
r
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fault recognised".
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Any system faults that are stored will be displayed one after the other and printed out. The V.A.G 1551 will thent. C rig
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transmit the next address word. pyri by
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-> The automatic test sequence has ended when following is indicated on display:
V.A.G SELF-DIAGNOSIS HELP
1 - Rapid data transfer*
2 - Flash code output*

- Erase all fault memories and then carry out a road test.

During the road test the following operating conditions must be fulfilled:
- The coolant temperature must exceed 80 °C .
- When the temperature is reached, the operating conditions
Idling
Part throttle
Full throttle
Overrun
must be attained several times.
- At full throttle the speed must exceed 3500 rpm.

- Again interrogate the fault memories of all control units using the "automatic test sequence".

If no fault is stored:

- Press the ⇒key.

-> Indicated on display:

Rapid data transfer HELP
Select function XX

1.6 - Interrogating and erasing fault memory 7

 1AV injection and ignition system - Edition 08.1997
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

Note:

If the self-diagnosis has not detected a fault, use the appropriate fault table in "Fault finding engine" binder for
further fault finding.

1.7 - Fault table

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◆ The fault tables are listed according to the 5 digit fault code on the left.
s

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le

◆ Explanation of the fault types (e.g. "open circuit/short circuit to earth"):

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=> Fault reader operating instructions
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◆ If components are indicated as faulty:
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First check the wiring and connectors to these components as well as the system earth connections ac‐
hole

spec
cording to current flow diagram. This is particularly relevant if faults are output as "occurring
es, in part or in w

sporadically" (SP).

t to the co
V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy

rrectness of i
No fault recognized! If a complaint exists: --- Continue fault finding according to
Fault not recognised during self-di‐ fault table, in "Engine fault finding"
l purpos

agnosis binder.

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy

nform
ercia

00282
m

a
com

Throttle valve positioner - tion in

V601)
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te o

thi

Short to earth - Short to earth - Cold starting problems - Check V60

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- V60 defective/sticking - Cold idling problems =>Page 41 , checking

rp

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in closed direction - Hard load changes throttle valve control part

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Short to positive - Short to positive
. Cop
- Idling problems py
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- V60 defective/sticking
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Open circuit Prote
- Wiring open circuit
AG.

Signal out of tolerance - Short to earth and/or

battery positive

1) The throttle valve positioner (V60) is a component of the throttle valve control part (J338).

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00516
Idling switch -F601)
Unplausible signal - F60 defective - Idling problems - Carry out basic setting
- Driving characteristics =>Page 41 , check throt‐
faults when driving off tle valve control part
00518
Throttle valve potentiometer
-G692)
Short to earth - G69 defective - Poor throttle response - Carry out basic setting
- Wiring has short to - Hard load changes =>Page 64
earth

8 01 - Self-diagnosis
 n AG. Volkswagen AG do
lkswage es n
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1AV injection ir se and ignition system - Edition 08.1997
d ran
tee
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V.A.G 1551 print-out Possible causes sof
s fault Possible effects Fault remedy c

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e
Open circuit/Short to - Open circuit in earth - Increased emission val‐ - Check G69

nl

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positive wire ues =>Page 41 , checking

itte

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- Wiring has short to - No full throttle recognition throttle valve control part

erm

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positive

ot p
- G69 defective

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hole
1) The idling speed switch (F60) is a component of the throttle valve control part (J338).

spec
es, in part or in w
2) The throttle valve potentiometer (G69) is a component of the throttle valve control part (J338).

t to the co
V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy

rrectness of i
00519
Intake manifold pressure sender - l purpos
G71
Short to positive - Wiring has short to positive - Increased emissions values - Check G71

nf
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=>Page 47

orm
m

Open circuit/short to earth - Open circuit in earth wire - Poor throttle response

atio
m

- Wiring has short to earth - Hard load changes

o

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- G71 defective

thi
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Implausible signal - Loose contact

iv

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- G71 defective
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V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
Cop py
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00522
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Coolant temperature sender -G62 Prote
cted AG.
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Short to earth - Wiring has short to earth - Poor cold starting - Check G62
- G62 defective - Poor hot starting =>Page 49
Open circuit/short to positive - Wiring open circuit or short
to positive
- G62 defective
00523
Intake air temperature sender -
G42
Short to earth - Wiring has short to earth - Poor hot starting - Check G42
- G42 defective - Increased emissions values =>Page 52
Open circuit/short to positive - Wiring open circuit or short
to positive
- G42 defective

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00524
Knock sensor 1 -G61
Signal too small - Wiring open circuit or - Ignition timing point has - Check G61
short to earth been retarded by 15 < ° => Page 81
- G61 defective - Reduced performance
- High fuel consumption
00525
Lambda probe -G39
Short to positive - Wiring has short to posi‐ - No Lambda control - Check Lambda probe and
tive Lambda control
- G39 defective =>Page 36
Signal too large - G39 defective
Signal too small - G39 defective
- Wiring has short to earth

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00529

1.7 - Fault table 9

 1AV injection and ignition system - Edition 08.1997

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
Rpm information missing
No signal - Hall sender (G40) in distributor defective - Engine does not start - Check G40
- Wiring open circuit => Page 78
- Wiring has short to positive
- Wiring has short to earth
=> Current flow diagrams, Electrical fault finding and Fitting locations binder
V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00530
Throttle valve positioner/potenti‐
ometer -G881)
Open circuit/short to - Wiring open circuit or - Cold starting problems - Check G88
positive short to positive - Idling speed not within =>Page 41 , check
- G88 defective tolerances throttle valve control part
Short to earth - Wiring has short to - Cold idling speed prob‐
- earth lems
- G88 defective - Rough idling
00532
Supply voltage
Signal too large - Battery voltage above - No idling speed adap‐ - Check alternator
16.3 V tion
1) The throttle valve positioner/potentiometer (G88) is a component of the throttle valve control part (J338).
V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00609
Ignition output 1
Short to positive - Wiring to ignition trans‐ - Engine does not start - Check ignition transformer
former has short to positive =>Page 79
Open circuit/short to - Wiring open circuit in wagen AG. Volkswagen AG do
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earth earth wire y Vol
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- Wiring has short
ris
ed to
b
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01087 au
th or
ac
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Basic setting not carried The throttle
s valve control --- - Carry out basic setting
ce
e

out part learning sequence has

nl

=>Page 64
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not been completed

itte

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01126
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Engine speed signal

wit
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Short to positive - Wiring open circuit or - Rev. counter does not - Check speed signal
hole

short to positive operate => Page 12 , final control

spec

diagnosis
es, in part or in w

t to the co

Short to earth - Wiring has short to earth

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
rrectness of i

01247
l purpos

Activated charcoal filter solenoid

valve 1 -N80
nform
ercia

Open circuit/short to earth - Wiring open circuit or - Rough idling - Check N80
short to earth - Fuel odours => Page 12 , final control
m

at
om

- N80 defective diagnosis

ion
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Short to positive - Wiring has short to posi‐

o

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te

tive
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- N80 defective
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V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
Co
Cop py
t. rig
01249
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10 01 - Self-diagnosis
 1AV injection and ignition system - Edition 08.1997

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
No.1 cyl. injector -N30
Short to positive - N30 defective - Increased emissions val‐ - Check N30...N33
- Wiring has short to pos‐ ues => Page 55 , checking in‐
itive - Poor starting jectors
Open circuit/short to - N30 defective - Poor throttle response
earth - Open circuit in earth - Rough idling
wire
- Short to earth
01250
No. 2 cyl. injector -N31
Short to positive See fault code 01249, Cyl. 1
Open circuit/short to
earth

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
01251
No. 3 cyl. injector -N32
Short to positive See fault code 01249, Cyl. 1
Open circuit/short to earth
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No. 4 cyl. injector -N33 ised b ara
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Short to positive ut ho
See faulte o code 01249, Cyl. 1
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Open circuit/short
s to earth ce
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V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
itte

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01259
ility
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Fuel pump relay -J17

wit
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Short to positive - Wiring to ignition trans‐ - Engine does not start - Check ignition transformer
hole

spec

former has short to posi‐ =>Page 79

es, in part or in w

tive
t to the co

Open circuit/short to earth - J17 defective

- Wiring open circuit in
earth cable
rrectness of i

- Short to earth
l purpos

17978
Engine control unit blocked - Attempted manipulation - Engine starts briefly and - Adapt engine control unit
nform
ercia

- Short in communication then stops again to electronic immobilizer =>

cable Page 65
m

at

- Incorrect coding Check electronic immobiliz‐

om

ion

- Immobilizer control unit er:

c

in t
or

defective/missing => Repair group 96; Servic‐

his
ate

ing electronic immobilizer

do
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for

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V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
n

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65535
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Control unit defective - Control unit internally defective - Engine running problems - Renew J382
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- Attempted manipulation of control unit - Engine will not run => Page 63
lksw
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1.7 - Fault table 11

 1AV injection and ignition system - Edition 08.1997

2 - Final control diagnosis

2.1 - Final control diagnosis

2.2 - Performing final control diagnosis n AG. Volkswagen AG do

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The final control diagnosis activates the uthfollowing components in the stated sequence:
o
or
a ac
ss
1. Throttle valve positioner (V60)

ce
e
nl

pt
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an
itte

2. Activated charcoal filter solenoid valve 1 (N80)

y li
erm

ab
ility
ot p

3. Engine speed signal

wit
, is n

h re
hole

4. Fuel pump relay (J17)

spec
es, in part or in w

t to the co
5. Engine/air conditioner compressor electrical connection

Special tools, testers, measuring instruments and auxiliary items required

rrectness of i
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
l purpos

◆ Test box V.A.G 1598/18

◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Diode test lamp V.A.G 1527

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◆ Adapter set V.A.G 1594

rm
m

◆ Current flow diagram

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Check conditions

thi
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• Throttle valve potentiometer (G69) must be OK.

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• Fuses 15, 18 and 21 must be OK.
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Test requirements for vehicles with air conditioning system
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• Vehicle at room temperature (warmer than + 15 °C). Prote
cted AG.
agen
• Air conditioning system must be switched on.
• Select lowest temperature and highest blower speed.

Notes:
If the final control diagnosis is to be repeated without the engine being started in between time, switch ignition
off for approx. 20 seconds.
Work sequence

- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
with the "Address word" 01.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Operate fault reader taking into account the information on the display:
- Press keys 0 and 3 for the function "Final control diagnosis".

-> Indicated on display:

Rapid data transfer Q
03 Final control diagnosis

12 01 - Self-diagnosis
 1AV injection and ignition system - Edition 08.1997
Activate throttle valve positioner (V60):

- Confirm input with Q key.

-> Indicated on display:

Final control diagnosis
Throttle valve positioner-V60

The throttle valve positioner must open and close the throttle valve until switching to the next final control
by pressing the ⇒key.

If the throttle valve positioner does not move:

- Check throttle valve positioner

=>Page 41 , checking throttle valve controlwapart
gen AG
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doe
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Activate solenoid valve 1 for activated ris
echarcoal
d filter (N80): ara
nte
utho eo
ra
- Press ⇒key. ss
a c

ce
e
nl

pt
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-> Indicated on display:

an
itte

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erm

ab
Final control diagnosis

ility
Activ. charcoal filter solenoid valve
ot p

1 -N80

wit
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hole

The solenoid valve (right-hand suspension turret) must click, until activating the next final control element

spec
by pressing ⇒key.
es, in part or in w

t to the co
- Pull hose off activated charcoal filter at solenoid valve.
- Connect an auxiliary hose to the vacant valve connection.

rrectness of i
- Blow into auxiliary hose during final control diagnosis (in direction of throttle valve control part).
Valve must open and close
l purpos

If the solenoid valve does not click:

nform
ercia

- Continue check => Page 14 .

m

at
om

Display engine speed signal: ion

c

in t
or

his
ate

Note:
do
priv

cum
for

The test is only possible for vehicles with a rev. counter. On vehicles without rev. counter switch to the next
en
ng

t.
yi
final control by pressing the ⇒ key.
Co
Cop py
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- Press ⇒key.
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-> Indicated on display:
Final control diagnosis
Engine speed signal

The rev. counter must display approx. 3000 rpm, until next final control element is activated by pressing the
⇒key.

If no display appears:

- Check the rev. counter.

=> Current flow diagrams, Electrical fault finding and Fitting locations, Fuel supply system

Actuate fuel pump relay (J17):

- Press ⇒key.

-> Indicated on display:

2.2 - Performing final control diagnosis 13

 1AV injection and ignition system - Edition 08.1997

Final control diagnosis

Fuel pump relay J17

The fuel pump relay (on the relay plate with fuse box, relay position 12) must click until switching to the next
final control by pressing the ⇒key.

Note:
During the activation of the fuel pump relay the fuel pump must be heard to run at intervals.
If the relay does not click:
- Check fuel pump relay:

=> Current flow diagrams, Electrical

wage
n fault
AG. Vofinding anddFitting
lkswagen AG
oe locations, Fuel supply system
olks s no
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Check electrical connection
ise
d b to air conditioner: ara
nte
r
ho eo
Note: aut ra
ss c

ce
e

The test step is only for vehicles with air conditioner. On vehicles without air conditioner end final control diag‐
nl

pt
du

nosis by pressing ⇒key.

an
itte

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erm

ab
-> Indicated on display:

ility
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wit
, is n

Final control diagnosis

h re
Engine/air cond. compr. electr.
hole

connection

spec
es, in part or in w

t to the co
The air conditioner compressor magnetic coupling must click, until ending final control diagnosis by pressing
⇒key.

If the magnetic coupling does not click: rrectness of i

l purpos

- Check air conditioner.

=> Heater, air conditioner

nform
ercia

- Press ⇒key.
m

at
om

ion
c

in t

-> Indicated on display:

or

his
ate

Rapid data transfer HELP

do
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Select function XX
um
for

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t.
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- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
Co
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- Switch off ignition. t. C rig
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Note:
by lksw
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After completion of the final control diagnosis switch off ignition. If the ignition is not switched off before at‐
tempting to start, the engine will not run, as the injectors and the ignition transformer will not be activated.
Continuation of check when the activated charcoal filter solenoid 1 does not click:

14 01 - Self-diagnosis
 1AV injection and ignition system - Edition 08.1997
- -> Pull connector -1- off solenoid valve -2- and connect diode test lamp V.A.G 1527 with aux. cables from
V.A.G 1594 to disconnected connector.
The LED must flash (bright/darker)

LED flashes:

- Proceed with final control diagnosis until completed.

- Switch off ignition.
- Renew solenoid valve -2-.

=> Repair group 20; Removing and installing parts of activated charcoal filter system Removing and installing
parts of activated charcoal filter system

LED does not flash:

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spec
- Proceed with final control diagnosis until completed.
es, in part or in w

- Switch off ignition.

t to the co
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Check wire for open circuit between test box sockets 3 and 2 pin connector contact 1, according to current
flow diagram.
Wire resistance: max. 1.5 ω rrectness of i
l purpos

- Additionally check wire for short to battery positive and earth.

Specification: ∞ω
- Check wire between 2 pin connector contact 2 and relay plate for open circuit using to current flow diagram.
nform
ercia

Wire resistance: max. 1.5 ω

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a
com

ti

If no wiring fault is detected:

on in
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te o

thi

- Renew engine control unit

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iva

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=> Page 28 , item 28

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3 - Measured value blocks
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3.1 - Measured value blocks

3.2 - Read measured value block and basic settings

The measured values in the functions read measured value block and basic setting are described during the
individual component test. This table serves only as an overview.

Note:

To change to another display group proceed as follows:

2.2 - Performing final control diagnosis 15

 1AV injection and ignition system - Edition 08.1997

Display group V.A.G 1551 V.A.G 1552

Higher Press key 3 Press ↑key
Lower Press key 1 Press ↓key
Skip Press key C Press key C

3.3 - Display group overview

Display group 0 (decimal displayed value)

Test conditions
▪ Engine runs at idling speed
▪ The coolant temperature is at least 80 °C
▪ The electrical consumers are switched off
Display zones Specification Corresponds to
1 2 3 4 5 6 7 8 9 10 Engine speed 71...67 825...875 rpm1)
Injection period 4...10 2.25...5.00 ms
Throttle valve angle 23...42 10...18 <°
Not relevant --- ---
Not relevant --- ---
1 2 3 4 5 Lambda probe signal 0...20 0...0.1
123...195 0.6...0.95 V
Intake manifold pressure 45...84 300...480 mbar
Coolant temperature 37...19 80...105 °C
Battery voltage 187...226 12.0...14.5 V
Intake air temperature 156...44 15...70 °C

1) Up-to-date specifications:

=> Exhaust emissions test binder

. Volkswagen AG Display zones

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Display group 1 orise nte
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Display xxxxrpm
sxxxxxxxx
au xx.x °C x.x V r ac
s
Indicated Engine speed Coolant temperature Lambda probe voltage Adjustment conditions4)
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pt
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Specification1) 825...8752)3) 80...105 0.1...0.95 fluctuating 00000000

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Display group 2
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Display xxxx rpm xx.xx ms xx.x V xx.x °C

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Indicated Engine speed Injection period Battery voltage Intake air temperature
hole

spec

Specification1) 825...8752)3) 2.25...5.00 12.0...14.5 V 15...70

es, in part or in w

t to the co

Display group 3
Display xxxx rpm xxx % xx <° xx.x %
Indicated Engine speed Engine load Throttle valve angle Position of throttle valve by throt‐
rrectness of i

tle valve positioner

l purpos

Specification1) 825...8752)3) 45...84 9...18 17...29

nform
ercia

Display zones
1 2 3 4
m

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Display group 4
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or

Display xxxx rpm xxx % xxx xxxxxxxx

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ate

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Indicated Engine speed Engine load Speed signal Operating condition4)

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16 01 - Self-diagnosis
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Prote AG.
 1AV injection and ignition system - Edition 08.1997

Display zones
Specification1) 825...8752)3) 45...84 255 01000000

1) The specifications must be attained when:

- engine runs at idling speed,

- the coolant temperature is at least 80 °C and

- electrical consumers are switched off

2) The control unit increases idling speed under following conditions:

- When the battery voltage is too low: up to 900 rpm

- After a long full throttle drive and higher temperatures: up to 960 rpm

3) Up-to-date specifications: AG. Volkswagen AG d

agen oes
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=> Exhaust emissions test binder d by
V gu
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4) Significance of numbers in s8audigit
t
number block => Page 17 . ra
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Display zones

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1 2 3 4
erm

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Display group 5
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Display xxxx rpm xxx %

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Indicated Engine speed Duty cycle solenoid valve 1 for activated charcoal filter --- ---

spec
urposes, in part or in wh

Specification1) 825...8752)3) 6...19 --- ---

t to the co
1) The specifications must be attained when:

rrectne
- engine runs at idling speed,

ss
- the coolant temperature is at least 80 °C and
o
cial p

f inform
- electrical consumers are switched off
mer

atio
m

2) The control unit increases idling speed under following conditions:

o

n
c

i
or

n thi
te

- When the battery voltage is too low: up to 900 rpm

sd
iva

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cum
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- After a long full throttle drive and higher temperatures: up to 960 rpm
en
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3) Up-to-date specifications:
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=> Exhaust emissions test binder cted agen
Prote AG.

Significance of figures in 8 digit number block

Significance when displayed digit = 1

x x x x x x x x Adjustment conditions (display group 1) Operating condition (display group 4)
1 Not relevant Overrun
1 Not relevant Idling speed
1 Air conditioner compressor switched on Part load
1 Idling switch open1) Full load
1 Fault in the Lambda control2) Not relevant
1 Throttle valve opened Not relevant

3.3 - Display group overview 17

 AG. Volkswagen AG d
agen oes
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1AV injection
s au and ignition system - Edition 08.1997 ra
c
s

ce
le
un

pt
Significance when displayed digit = 1

an
d
itte

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1 Speed above 2000 rpm Not relevant
erm

ab
ility
1 Coolant temperature below 80 °C Not relevant
ot p

wit
is n

h re
ole,

1) The problem may be: e.g. the accelerator cable is set too tight.

spec
urposes, in part or in wh

2) Self-diagnosis will not register all faults. If a 1 is displayed even when no faults are stored, check Lambda

t to the co
probe and Lambda control =>Page 36 .

rrectness o
cial p

f inform
mer

atio
om

n
c

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te

sd
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cum
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fo

en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

18 01 - Self-diagnosis
 1AV injection and ignition system - Edition 08.1997

24 - Mixture preparation, Injection

1 - Servicing injection system

1.1 - Servicing injection system

AG. Volkswagen AG d
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spec
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t to the co
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cial p

f inform
mer

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n
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1.2 - Fitting locations overview

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1 4 pin connector gh ht
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◆ For Lambda probe (G39) by c lksw
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2 Lambda probe (G39), 55 Nm
AG.

◆ Location: In front exhaust pipe

3 Intake manifold pressure sender (G71) with intake air temperature sender (G42)
4 Throttle valve control part (J338)
5 Knock sensor 1 (G61)
◆ =>Page 74

1.1 - Servicing injection system 19

 AG. Volkswagen AG d
agen oes
olksw not
1AV injection and ignition system d by V - Edition 08.1997 gu
ara
ise nte
or eo
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6 Ignition transformer (N152) s aut ra
c
s
◆ =>Page 72

ce
le
un

pt
7 Fuel rail

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ility
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wit
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spec
urposes, in part or in wh

t to the co
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f inform
mer

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rig ht
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8 Earth connection
9 Engine control unit
(control unit for 1AV fuel injection and ignition system -J382)
10 Fuel pressure regulator
11 Distributor
◆ =>Page 73
12 Central connector
13 Earth connection
14 Coolant temperature sender (G62)
◆ Identification: yellow ring
15 Injector (N30...N33)
16 Air cleaner
◆ Removing => Page 34 ,
Fig. 3
17 Spark plug, 25 Nm

20 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997
◆ =>Page 76

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18 Oil pressure switch

mer

19 Activated charcoal filter solenoid valve 1 (N80)

atio
om

◆ Activated charcoal filter system

c

i
or

n thi
te

sd
a

=> Repair group 20, removing and installing parts of the fuel supply system, removing and installing parts of
iv

o
pr

the activated charcoal filter system

um
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fo

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op
20 Activated charcoal filter C py
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gh
◆ In right-hand wheel housing
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pyri by
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◆ Activated charcoal filter system
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Prote AG.

=> Repair group 20, removing and installing parts of the fuel supply system, removing and installing parts of
the activated charcoal filter system

1.3 - General notes on injection

Servicing ignition part:

1.2 - Fitting locations overview 21

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
1AV injection and ignition system - Edition 08.1997
orise nte
h eo
aut ra
=> Repair group 28 ss c

ce
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un

pt
Notes:

an
d
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rm

ab
pe
◆ The engine control unit is equipped with self-diagnosis. Before carrying out repairs and fault finding the fault

ility
ot
memory must be interrogated. Also the vacuum hoses and connections must be checked (unmetered air).

wit
, is n
◆ Components marked with * are checked via the self diagnosis

h re
hole
=> Page 6 , interrogating and erasing fault memory.

spec
◆ Components marked with **can be checked with the final control diagnosis => Page 12 .

es, in part or in w

t to the co
◆ Disconnecting and connecting the battery must only be done with the ignition switched off, otherwise the
engine control unit could be damaged.
◆ For trouble-free operation of the electrical components a voltage of at least 11.5 V is necessary.

rrectness of i
◆ If the engine starts, runs for a short period and then stops, after fault finding, repairs or component tests,
then the fault may lie with the immobilizer which is blocking the engine control unit. The fault memory must

l purpos
be interrogated and if necessary the control unit matched => Page 65 .
◆ Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the
engine and damage the Lambda probe.

nform
ercia
◆ During some checks it is possible that the control unit will recognise and store a fault. Therefore after com‐
m
pleting all checks and repairs the fault memory must be interrogated and if necessary erased.

a
com

tio
=> Page 6 , interrogating and erasing fault memory

n in
◆ The "learnt" values will be erased if the control unit is disconnected from the current supply. Engine running
r
te o

thi
problems may occur until the control unit has "relearnt" all values.

s
iva

do
◆ Always renew spring-type hose clips with screw-type hose clips.
r
rp

cum
fo

en
ng

t.
Safety precautions =>Page 35
yi Co
Cop py
t. rig
gh ht
yri
Rules for cleanliness => Page 35 p by
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by c lksw
cted agen
Prote AG.
Technical data => Page 35

Checking intake system for leaks (unmetered air) => Page 60

22 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

1.4 - Removing and installing parts of the injection system

AG. Volkswagen AG d
agen oes
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au ra
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nl

pt
du

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erm

ab
ility
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wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
ercia

orm
m

atio
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n in
or c

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sd

1 To warm air intake

iva

o
r
rp

cu

◆ To warm air collecting plate on exhaust manifold

o

m
f

en
ng

2 To oil separator
t.
yi Co
op py
3 Air cleaner t. C rig
gh ht
yri
◆ Removing => Page 34 , p by
co Vo
by lksw
Fig. 3 Prote
cted AG.
agen
◆ Dismantling and assembling => Page 32
4 Screw

Note:

Loosening and tightening the screws -4- with a power screwdriver is only permitted if:

◆ The power tool speed is max. 200 rpm

◆ The tightening torque is set to max. 3 Nm

1.4 - Removing and installing parts of the injection system 23

 1AV injection and ignition system - Edition 08.1997

n AG. Volkswagen AG do
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spec
es, in part or in w

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nform
mercia

a
com

tion in
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s
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5 Connector
◆ 4-pin
◆ For intake manifold pressure sender (G71) with intake air temperature sender (G42)
6 Connector
◆ 8 pin
◆ For throttle valve control part (J338)
7 Cable guide
◆ Clipped on fuel manifold
8 10 Nm
9 Fuel rail with injectors
◆ Dismantling and assembling => Page 29
10 Earth wire
◆ For throttle valve control part
11 Vacuum hose

24 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

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spec
es, in part or in w

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nform
mercia

a
com

tion in
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te o

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s
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do
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12 To brake servo
13 Return hose
◆ Secure with spring-type clips on fuel manifold
◆ Blue or blue markings
14 20+1 Nm
◆ Tighten bolts from inside to outside
◆ Ensure tightening torque is correct, otherwise the intake manifold bushes will work into the cylinder head
15 Intake manifold
◆ Dismantling and assembling => Page 30
16 O ring
◆ Renew
17 Thermostat housing
18 O ring
◆ Renew if damaged

1.4 - Removing and installing parts of the injection system 25

 1AV injection and ignition system - Edition 08.1997
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
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fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
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Prote AG.

19 Coolant temperature sender (G62)*

◆ With coolant temperature gauge sender (G2)
◆ Identification: yellow ring
◆ If necessary release pressure in cooling system before removing
◆ Checking =>Page 49
◆ Resistance graph
=>Page 34 , Fig. 1
20 Connector
21 Retaining clip
22 Lambda probe (G39)*, 55 Nm
◆ Location: In front exhaust pipe
◆ Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
◆ Checking Lambda probe and Lambda control
=> Page 36

26 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

n AG. Volkswagen AG do
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◆ Checking probe heating voltage supply => Page 38

pt
du

an
itte

◆ Check probe heating for continuity

y li
erm

ab
ility
ot p

23 4-pin connector
wit
, is n

◆ For Lambda probe and Lambda probe heating

h re
hole

◆ Secured to rear engine mounting on right, in direction of travel

spec

24 To fuel tank
es, in part or in w

t to the co

25 Securing plate
26 Connector
rrectness of i

◆ Only disconnect or connect with ignition switched off

27 10 Nm
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
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o

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f

en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.4 - Removing and installing parts of the injection system 27

 1AV injection and ignition system - Edition 08.1997

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

a
com

tion in

28 Engine control unit*

r
te o

thi

(control unit for 1AV fuel injection and ignition system -J382)
s
iva

do

◆ For injection system, Lambda regulation, activated charcoal filter solenoid valve, knock control, governed
r
rp

cum

speed, ignition and self-diagnosis

fo

en
g

◆ Location: in plenum chamber, left

n

t.
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◆ Renew => Page 63 C py
ht. rig
◆ Checking voltage supply => Page 66 rig ht
py by
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29 Supply hose by c lksw
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Prote
◆ Secure with spring-type clips on fuel manifold
AG.

◆ Black or white markings

30 To activated charcoal filter solenoid valve 1 (N80)
◆ Activated charcoal filter system

=> Repair group 20, removing and installing parts of the fuel supply system, removing and installing parts of
the activated charcoal filter system

28 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

1.5 - Dismantling and assembling fuel rail with injectors

AG. Volkswagen AG d
agen oes
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ility
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wit
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spec
urposes, in part or in wh

t to the co

1 Fuel manifold
2 Retaining clip
◆ Ensure seated correctly at injector and fuel rail
rrectne

3 Retaining clip
4 Fuel pressure regulator
ss o

◆ Checking fuel pressure regulator and holding pressure => Page 57

cial p

f inform

5 O ring
mer

◆ Renew if damaged
atio
om

6 Injectors (N30...N33)*
c

i
or

n thi

◆ Checking => Page 55

te

sd
va

◆ Resistance 14...17 ω
i

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pr

cum
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fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
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Prote AG.

1.5 - Dismantling and assembling fuel rail with injectors 29

 1AV injection and ignition system - Edition 08.1997

1.6 - Dismantling and assembling intake manifold

AG. Volkswagen AG d
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spec
es, in part or in w

t to the co
rrectness of i
l purpos

1 Intake manifold pressure sender (G71)* with intake air temperature sender (G42)*
nf
ercia

◆ Resistance values for intake air temperature sender orm

m

atio
=>Page 34 , Fig. 2
om

n in

2 O ring
or c

thi
e

◆ Renew if damaged
t

sd
iva

3 Intake manifold
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cu
o

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f

4 Throttle valve control part (J338)*

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ng

t.
yi Co
◆ Checking => Page 41 Cop py
t. rig
◆ Components of the throttle valve control part (J338): yri
gh by
ht
Throttle valve positioner (V60), throttle valve potentiometer (G88), throttle valve potentiometer (G69) and
op Vo
by c lksw
idling switch (F60) cted agen
Prote AG.

30 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

AG. Volkswagen AG d
agen oes
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spec
es, in part or in w

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rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

If the control unit is replaced:

do
r
rp

◆ Perform basic settings => Page 64

um
fo

en
ng

t.
yi Co
5 O ring Cop py
ht. rig
◆ Renew if damaged rig ht
py by
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6 10 Nm
by c lksw
cted agen
Prote AG.
7 Earth wire
◆ For throttle valve control part
8 From fuel rail
9 To fuel tank

1.6 - Dismantling and assembling intake manifold 31

 1AV injection and ignition system - Edition 08.1997

1.7 - Dismantling and assembling air cleaner

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mercia

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fo

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Removing air cleaner => Page 34 , Fig. 3

1 Air cleaner cover

Note:

If the cover screws are loosened or tightened with a power tool the lower part of the thread can be damaged.
Therefore the use of a power tool is only permissible when:

◆ The power tool speed is max. 200 rpm

◆ The tightening torque is set to max. 3 Nm

2 Filter element
3 Air cleaner lower part

32 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

AG. Volkswagen AG d
agen oes
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d b ara
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nl

pt
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an

4 Gasket
itte

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ab

◆ Renew if damaged
ility
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5 Crankcase breather hose

wit
, is n

6 Warm air intake

h re
hole

7 Air intake housing with regulating flap

spec
es, in part or in w

◆ Check intake air preheating => Page 60

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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pyri by
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Prote AG.

1.7 - Dismantling and assembling air cleaner 33

 1AV injection and ignition system - Edition 08.1997
-> Fig. 1 Resistance values for coolant temperature sender (G62)

AG. Volkswagen AG d
agen oes
The diagram is divided into two temperature ranges:
Vol
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gu
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A- From 0...50 °C tho
r eo
B- From 50...105 °C ss
au ra
c

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Examples:

an
d
itte

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erm

ab
◆ 30 °C is in range A and corresponds to a resistance of 1.5...2.0 kω

ility
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◆ 80 °C is in range B and corresponds to a resistance of 275...375 ω

wit
is n

h re
ole,

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urposes, in part or in wh

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rrectness o
cial p

f inform
mer

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om

n
c

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-> Fig.2 Resistance values for intake air temperature sender (G42)
p

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t.
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Cop py
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Examples: pyri
gh by
Vo
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cted
◆ 20 °C corresponds to a resistance from 2340...2680 ω
agen
Prote AG.
◆ 80 °C corresponds to a resistance from 290...330 ω

-> Fig. 3 Removing air cleaner

- Loosen air cleaner at securing screws marked by arrows.

Note:

If the securing screws are loosened or tightened with a power tool the thread in the intake pipe can be damaged.
Therefore the use of a power tool is only permissible when:

◆ The power tool speed is max. 200 rpm

◆ The tightening torque is set to max. 3 Nm

34 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

1.8 - Safety precautions

Warning!
Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release
pressure by carefully loosening the connection.

To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be
noted:

◆ Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed.
◆ The ignition must be switched off before connecting or disconnecting injection or ignition system wiring or
tester cables.
◆ If the engine is to be turned at starter speed, without starting, e.g. when checking compressions, pull plug
off Hall sender (distributor).

Observe following if test and measuring instruments are required during a test drive:

◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.

If test and measuring instruments are operated from front gepassenger's

n AG. Volkswageseat
n AG dand the vehicle is involved in
swa oe
an accident, there is a possibility that the person ysitting
Volk in this seat may receives nserious
ot g
ua
injuries when the
airbag is triggered. ris
ed b ran
t ee
tho or
s au ac
s

ce
le

1.9 - Rules for cleanliness

un

pt
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d
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ab
pe

ility
ot

When working on the fuel supply/injection system, pay careful attention to the following "5 rules":

wit
, is n

h re
hole

◆ Thoroughly clean all unions and the adjacent areas before disconnecting.

spec
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
es, in part or in w

t to the co
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.

rrectness of i
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
l purpos

Do not work with compressed air if this can be avoided.

Do not move vehicle unless absolutely necessary.
nform
mercia

a
com

1.10 - Technical data

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Engine code AEE, ALM

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Idling speed rpm 825...8751)2)

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1.8 - Safety precautions 35

 1AV injection and ignition system - Edition 08.1997

Engine code AEE, ALM

Control unit version 1AV

1) Up-to-date specifications:

=> Exhaust emissions test binder

2) The control unit increases idling speed under following conditions:

- When the battery voltage is too low: up to 900 rpm

- After a long full throttle drive and at higher temperatures: up to 960 rpm

- When air conditioner is switched on: to approx. 900 rpm

3) If replaced carry out basic setting => Page 64

2 - Check components and functions

2.1 - Check components and functions

2.2 - Checking Lambda probe and Lambda control

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Special tools, testers, measuring instruments
ed b and auxiliary items required ara
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◆ Fault reader V.A.G 1551 orssvehicle system tester V.A.G 1552 with cable V.A.Gac 1551/3
a
◆ Test box V.A.G 1598/18
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un

pt

◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715

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◆ Adapter set V.A.G 1594

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◆ Current flow diagram

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Check conditions
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• Basic setting OK.

es, in part or in w

• Exhaust system between cylinder head and catalyst free of leaks

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Test sequence
rrectness of i

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
l purpos

unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)
nform
ercia

-> Indicated on display:

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Rapid data transfer HELP

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Select function XX
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- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.
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-> Indicated on display:

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- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.
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-> Indicated on display:

36 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997
(1...4 = Display zones)
Read measured value block 1
1 2 3 4

Only continue with the test when

• The coolant temperature is above 80 °C
-Display zone 2-
• The engine has then run for a further 2 minutes at idling speed

- Note Lambda probe voltage in display zone 3. The voltage must

fluctuate at least 30 times per minute
in range of
0... 1.0 V.

If the voltage change is slower, determine cause of afault.

gen AG=> Page n38
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es, in part or in w

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- -> Pull connector -1- off coolant temperature sender (G62) -2-. The probe voltage must

rrectness of i
increase
and then decrease back to the old control range.
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- Reconnect connector. The probe voltage must

decrease

nform
ercia

and then increase to the old control range.

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Note:
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The throttle valve must not be operated during the check, otherwise the connector disconnected from the control
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unit will be recognised as a fault.

r
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- Press ⇒ key.
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- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition

If no control is detected:
- Check Lambda probe heating => Page 38 .

2.2 - Checking Lambda probe and Lambda control 37

 1AV injection and ignition system - Edition 08.1997
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

n AG. Volkswagen AG
- -> Separate 4 pin connector to oLambda
lksw
age probe (G39) -1-.does
no
- Check wiring between test dbox
by V and connector for open circuitt according
gu
ara to current flow diagram.
Contact 3+socket 15horise nte
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Contact 4+socket a38ut ra
c
Wire resistance: sMax. 1.5 ω
s

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- Check wiring at connector contacts 3+4 for short circuit to contacts 1+2 according to current flow diagram.
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Specification: ∞ω

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If no wiring fault is detected:
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- Renew Lambda probe (G39) =>Page 26 , item 22 .

h re
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spec
Possible causes of fault if probe control frequency is too slow:
es, in part or in w

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◆ The slots or holes in probe body are blocked
◆ The probe vent hole in area of connecting wire is blocked
◆ The probe has been overheated (glazed)
rrectness of i
◆ The probe has been damaged by leaded fuel
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2.3 - Checking Lambda probe heating

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Special tools, testers, measuring instruments and auxiliary items required

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◆ Test box V.A.G 1598/18

te

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a

◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715

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◆ Adapter set V.A.G 1594

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Test conditions gh ht
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• Fuel pump relay must be OK
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• Fuse 18 must be OK.
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Checking voltage supply

38 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997
- -> Separate 4 pin connector to Lambda probe (G39) -1-.
- Connect multimeter using adapter cable from V.A.G 1594 to measure voltage on connector contacts 1+2.
- Start engine and measure voltage.
Specification: at least 11 V
- Switch off ignition.

If no voltage is present:

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Switch on ignition.
- Bridge test box sockets 1+25 with aux. cables from V.A.G 1594. The fuel pump must run.
- Observe display on multimeter.
Specification: min. 11 V

If the specification is not obtained:

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- Check wiring connections according to relay
lksw plate according to current
agen es n flow diagram.
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2.4 - Checking engine operating mode
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Note:
erm

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Check whether engine control unit recognises the engine operating modes (idling speed, part throttle, full throt‐
, is n

h re

tle, overrun).
hole

spec
es, in part or in w

Special tools, testers, measuring instruments and auxiliary items required

t to the co

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
rrectness of i

Test conditions
l purpos

• Coolant temperature at least 80 °C

nform
ercia

Test sequence
m

at
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io

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
n
c

in t
r

unit. When doing this the engine must be running at idling speed.
o

his
te

(Connecting fault reader and selecting engine control unit => Page 2 .)
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for

-> Indicated on display:

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Rapid data transfer HELP Cop py
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Select function XX rig by
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copy Vo
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- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.
agen
Prote AG.

-> Indicated on display:

2.3 - Checking Lambda probe heating 39

 AG. Volkswagen A
gen ignition system
1AV injection
olks
waand
G do
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o
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Read measuredorivalue block HELP nte
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Input display
aut group number XXX ra
ss c

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nl

- Press keys 0, 0 and 4 for "Display group number 4" and confirm entry with Q key.

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-> Indicated on display:

ility
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(1...4 = Display zones)

wit
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Read measured value block 4
hole

1 2 3 4

spec
es, in part or in w

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- Observe -8 digit number block- in display zone 4 :
(The right-hand 4 digits are of no consequence)

rrectness of i
Display in operating mode
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◆ Idling:

nform
ercia

2nd position from left must display 1

Display: 01000000
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◆ Part throttle:
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ate

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- Rev up evenly.
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3rd position from left must display 1

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Display:: 00100000 C py
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◆ Full throttle:
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- Briefly open throttle fully (throttle burst).

4th position from left must briefly display 1

Display: 00010000

◆ Overrun mode:

- Increase engine speed to above 3000 rpm.

- Close throttle valve abruptly.

As long as the engine speed is above 1400 rpm 1st position from left must display 1
Display: 11000000 (briefly)

Note:

Below 1400 rpm idling speed is again recognised.

- Press ⇒ key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

If the specifications are not attained:

- Interrogate fault memory, if necessary, repair fault and erase fault memory.
=> Page 6 , interrogating and erasing fault memory
- Check throttle valve potentiometer
=> Page 41 , Checking throttle valve control part.

40 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

2.5 - Checking throttle valve control part

Note:

If the throttle valve control part (J338) is removed and installed or replaced the basic setting must be performed
=> Page 64 .
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Test boxssV.A.G 1598/18 ra
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◆ Adapter set V.A.G 1594
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◆ Current flow diagram

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Checking idling switch

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- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
hole

spec
with the "Address word" 01.
es, in part or in w

(Connecting fault reader and selecting engine control unit => Page 2 .)

t to the co
-> Indicated on display:

rrectness of i
Rapid data transfer HELP
Select function XX
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- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

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ercia

-> Indicated on display:

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Read measured value block HELP
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Input display group number XXX

or

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ate

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- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.
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-> Indicated on display:
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- Observe -8 digit number block- in display zone 4 :

(The right-hand 4 digits are of no consequence)

4th position from left with closed throttle valve must display 0
Display: 00000000

- Slowly open throttle valve. After free travel, a stop is reached when opening throttle valve further the 4th
position from left must jump to 1
Display: 00010000

If the specifications are not obtained:

- Remove air cleaner => Page 34 , Fig. 3 .

Display Cause Continuation of

check
Always 1 Open circuit or short => Page 42
to positive
Always 0 Short to earth => Page 42

2.5 - Checking throttle valve control part 41

 olkswagen AG
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1AV injection and ignition system - Edition 08.1997
olks
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Continuation of check when display is always at 1 ir se nte
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es, in part or in w

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- -> Detach connector -1- from throttle valve control part -2-.
- Bridge connector contacts 3+7 with aux. cables from V.A.G 1594 and observe display.

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Display 0:
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- Press the ⇒key.

or

thi
e

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
t

sd
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- Switch off ignition.

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- Replace throttle valve control part
o

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=>Page 30 , item 4 .
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- Press the ⇒key. Prote AG.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Check voltage supply of throttle valve control part and wiring to control unit => Page 46 .

If the voltage supply and wiring is OK:

- Renew engine electronics control unit => Page 63 .

Continuation of check when display constantly shows 0

- -> Detach connector -1- from throttle valve control part -2-.

Display 1:

- Press the ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Replace throttle valve control part
=>Page 30 , item 4 .

42 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997
Display 0:
- Press the ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Check voltage supply of throttle valve control part and wiring to control unit => Page 46 .

If the voltage supply and wiring is OK:

- Renew engine electronics control unit => Page 63 .

Checking throttle valve positioner and throttle valvewapositioner

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Test conditions ris
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• Coolant temperature at least 80 °C

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Test sequence

y li
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ab
ility
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
ot p

wit
unit. When doing this the engine must be running at idling speed.
is n

h re
(Connecting fault reader and selecting engine control unit => Page 2 .)
ole,

spec
urposes, in part or in wh

-> Indicated on display:

t to the co
Rapid data transfer HELP
Select function XX

rrectne
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

ss
-> Indicated on display:

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Read measured value block HELP

form
mer

Input display group number XXX

atio
m

- Press keys 0, 0 and 3 for "Display group number 3" and confirm entry with Q key.
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-> Indicated on display:
iva

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(1...4 = Display zones)

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Read measured value block 3 yi

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1 2 3 4 Cop py
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- Check throttle valve positioner duty cycle in display zone 4. The duty cycle must fluctuate in range
cop Vo
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17...29 %. cted agen
Prote AG.

If the specification is not obtained:

- Press the ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Remove air cleaner => Page 34 , Fig. 3 .

2.5 - Checking throttle valve control part 43

 1AV injection and ignition system - Edition 08.1997
- -> Detach connector -1- from throttle valve control part -2-.
- Measure throttle valve positioner resistance between connector contacts 1+2.
Specification: 3...200 ω
- Check voltage supply of throttle valve control part and wiring to control unit => Page 46 .

If no fault is detected:
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- Replace throttle valve control part lksw
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=>Page 30 , item 4 . byV
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Checking throttle valve potentiometer aut
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Test conditions

itte

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• Coolant temperature at least 80 °C
ot p

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Test sequence
hole

spec
es, in part or in w

- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit

t to the co
with the "Address word" 01.
(Connecting fault reader and selecting engine control unit => Page 2 .)

rrectness of i
-> Indicated on display:
l purpos

Rapid data transfer HELP

Select function XX

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ercia

- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.
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-> Indicated on display:
c

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Read measured value block HELP

at

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Input display group number XXX

p

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- Press keys 0, 0 and 3 for "Display group number 3" and confirm entry with Q key.
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-> Indicated on display:
rig ht
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(1...4 = Display zones) by c lksw
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Read measured value block 3
1 2 3 4

- Read off throttle valve angle in display zone 3.The throttle valve opening angle is displayed in starting
position.
- Slowly open throttle valve fully and observe angle display in display zone 3. The figure must increase uni‐
formly over
the complete range.
- Press the ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.

If the figure does not increase uniformly:

- Replace throttle valve control part

=>Page 30 , item 4 .

If the display constantly shows 0 <° or is above 100 <°:

- Remove air cleaner => Page 34 , Fig. 3 .

Display Cause Continuation of check

0 <° Open circuit or short to => Page 45
positive

44 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

Display Cause Continuation of check

above Short to earth => Page 45
100 <°
Continuation of check when display 0 <°:

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spec
urposes, in part or in wh

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- -> Detach connector -1- from throttle valve control part -2-.
- Bridge connector contacts 5+7 with auxiliary cables from V.A.G 1594 and observe display.

rrectne
Display above 100 <°:
- Press ⇒key.

ss
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

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cial p

f i
- Switch off ignition.

nform
- Replace throttle valve control part
mer

=>Page 30 , item 4 .

atio
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or

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Display 0 <°:

thi
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- Press ⇒key.
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- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

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t.
- Switch off ignition.
yi Co
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- Check voltage supply of throttle valve control part and wiring to control unit => Page 46 . t. C rig
gh ht
pyri by
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If the voltage supply and wiring is OK:
lksw
cted agen
Prote AG.

- Renew engine electronics control unit => Page 63 .

Continuation of check when display is above 100 <°:

- -> Detach connector -1- from throttle valve control part -2-.

Display 0 <°:
- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Replace throttle valve control part

2.5 - Checking throttle valve control part 45

 1AV injection and ignition system - Edition 08.1997
=>Page 30 , item 4 .

Display above 100 <°:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition. en AG. V
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- Check voltage supply l wagthrottle
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valve controloepart
not and wiring to control unit => Page 46 .
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If the voltage supply
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- Renew engine electronics control unit => Page 63 .

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Checking voltage supply and wiring to control unit

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- Remove air cleaner => Page 34 , Fig. 3 .
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es, in part or in w

t to the co
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tion in
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s

- -> Detach connector -1- from throttle valve control part -2-.
iva

do
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- Connect multimeter to measure voltage at connector contacts 4+7.

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- Switch on ignition.
en
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t.
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Specification: min. 4.5 V
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- Switch off ignition.
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- Connect multimeter to measure voltage at connector contacts 3+7.
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- Switch on ignition.
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Specification: min. 9 V
AG.

- Switch off ignition.

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

46 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

- -> Check wiring between test box and connector for open circuit according to current flow diagram.
Contact 1+socket 2
Contact 2+socket 26
Contact 3+socket 10
Contact 4+socket 14
Contact 5+socket 41
Contact 7+socket 17
Contact 8+socket 16
Wire resistance: Max. 1.5 ω
- Additionally check wires for short to one another.
Specification: ∞ω

If no wiring fault is detected:

- Check voltage supply of engine control unit => Page 66 .

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2.6 - Checkingtho intake manifold pressure sender tee
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Special tools, testers, measuring instruments and auxiliary items required

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◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
ility
ot p

◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715

wit
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◆ Test box V.A.G 1598/18

h re

◆ Adapter set V.A.G 1594

hole

spec

◆ Current flow diagram

es, in part or in w

t to the co

Test sequence
rrectness of i

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
l purpos

(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

nf
ercia

orm

Rapid data transfer HELP

m

atio
m

Select function XX
o

n in
or c

thi

- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.
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-> Indicated on display:

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t.
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Read measured value block HELP op py
Input display group number XXX t. C rig
gh ht
pyri by
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- Press keys 0, 0 and 3 for "Display group number 3" and confirm entry with Q key.
by lksw
cted agen
Prote AG.

-> Indicated on display:

(1...4 = Display zones)

2.5 - Checking throttle valve control part 47

 1AV injection and ignition system - Edition 08.1997

Read measured value block 3

1 2 3 4

- Read off the displayed value for engine load in display zone 2 and note this value.
- Briefly open throttle valve. The engine load value must increase briefly.

If the display shows constantly 0 % or 100 %:

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Display Cause
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0% Open scircuit
s or short to => Page 48
earth ce
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100 % Short to positive => Page 49

itte

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rm

ab
pe

Continuation of check when display 0%:

ility
ot

wit
, is n

- -> Pull connector -1- off intake manifold pressure sender (G71) with intake air temperature sender (G42) -2-
h re
hole

(engine stops).
spec

- Bridge connector contacts 3+4.

es, in part or in w

t to the co

Display 100 %:
- Press ⇒key.
rrectness of i

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
l purpos

- Switch off ignition.

- Renew the intake manifold pressure sender (G71) with intake air temperature sender (G42) -2-
=> Page 30 , item 1 .
nform
mercia

Display 0 %:
a
com

tion in

- Press ⇒key.
r
te o

thi

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
s
iva

do

- Switch off ignition.

r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Check wiring between test box and connector for open circuit according to current flow diagram.
Contact 3+socket 37
Contact 4+socket 18

48 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997
Wire resistance: Max. 1.5 ω
- Additionally check wiring contact 4 for short to earth and to contact 1.
Specification: ∞ω

If no wiring fault is detected:

- Renew engine electronics control unit => Page 63 .

Continuation of check when display 100 %:

- -> Pull connector -1- off intake manifold pressure sender (G71) with intake air temperature sender (G42) -2-
(engine stops).
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Display 0 %: yV
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ir se
- Press ⇒key. tho tee
or
- Press keys 0 and 6 for the
key. ss
afunction
u
"End output" and confirm entry with the Qac
- Switch off ignition.

ce
e
nl

- Renew the intake manifold pressure sender (G71) with intake air temperature sender (G42) -2-
pt
du

an
=> Page 30 , item 1 .
itte

y li
erm

ab
ility
ot p

Display 100 %:
wit
, is n

h re
- Press the ⇒key.
hole

spec
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
es, in part or in w

- Switch off ignition.

t to the co

- Pull connector off engine control unit.

- Check wiring to control unit connector at 4 pin connector contact 4 for short to wire contact 3 and to battery
positive.
rrectness of i

Specification: ∞ω
l purpos

If no wiring fault is detected:

nf
ercia

- Renew engine electronics control unit => Page 63 .

orm
m

atio
om

n in
or c

2.7 - Checking coolant temperature sender

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

Special tools, testers, measuring instruments and auxiliary items required

t.
yi Co
Cop py
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
t. rig
gh ht
yri by
◆ Test box V.A.G 1598/18 cop Vo
by lksw
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715 cted agen
Prote AG.
◆ Adapter set V.A.G 1594
◆ Current flow diagram

Test sequence
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.

2.6 - Checking intake manifold pressure sender 49

 1AV injection and ignition system - Edition 08.1997
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.
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-> Indicated on display: Vol
ks ot g
by ua
(1...4 = Display zones) rised ran
tee
o
Read measured valueuthblock 1 or
1 2 3
s a 4 ac
s

ce
le
un

pt
- Note coolant temperature value in display zone 2.

an
d
itte

y li
erm

ab
ility
Display Cause Continuation of
ot p

wit
check
is n

h re
ole,

-40 °C Open circuit or => Page 50

spec
short to positive
urposes, in part or in wh

t to the co
Approx. 128 °C Short to earth => Page 51
Approx. coolant --- Only if spora-
temperature1) dic faults
have been rrectne
detected:2)
s

=> Page 52
s o
cial p

f inform

1) If a temperature is displayed which deviates greatly from the ambient temperature of the sender, check
mer

sender wiring for transfer resistances.

atio
om

n
c

2) Check is only possible when the engine is cold.

or

n thi
te

sd
iva

o
r

Continuation of check when display -40 °C:

p

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- -> Pull 4 pin connector -1- off coolant temperature sender (G62) -2-.
- Bridge connector contacts 1+3 using aux. cables from V.A.G 1594 and observe display.

Display approx. 128 ° C:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.

50 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997
- Renew coolant temperature sender -2- => Page 26 , item 19 .

Display -40 ° C:
- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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tho eo
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ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Check wire between test box socket 42 and 4 pin connector contact 3 for open circuit according to current

rrectness of i
flow diagram.
Wire resistance: Max. 1.5 ω
l purpos

- Check wiring additionally for short circuit to battery positive.

Specification: ∞ω
- Check wire between test box socket 17 and 4 pin connector contact 1 for open circuit according to current

nform
ercia

flow diagram.
m

Wire resistance: Max. 1.5 ω

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

If no fault in wire is detected:

- Renew engine electronics control unit => Page 63 .

Continuation of check when display 128 °C:

- -> Pull 4 pin connector -1- off coolant temperature sender (G62) -2-.

Display -40 ° C:
- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Renew coolant temperature sender -2- => Page 26 , item 19 .

Display approx. 128 ° C:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.

2.7 - Checking coolant temperature sender 51

 1AV injection and ignition system - Edition 08.1997
- Pull connector off engine control unit.
- Check wire between control unit connector and 4 pin connector contact 3 for short to wire contact 1 and to
vehicle earth, according to current flow diagram.
Specification: ∞ω

If no fault in wire is detected:

- Renew engine electronics control unit => Page 63 .

Continuation of check when display = coolant temperature:

Functional check of sender

- Observe coolant temperature value in display zone 2, whilst engine is running. The temperature figure must
increase uniformly and without interruption.

Notes:

◆ If the display on fault reader jumps by 2...5 °C, it is a control unit fault and not caused by a defective sender.
◆ If irregular engine running occurs in certain temperature ranges and the temperature figure does not increase
without interruption, the temperature signal is temporarily interrupted and the sender must be renewed.

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

2.8 - Checking intake air temperature sender

Special tools, testers, measuring instruments and auxiliary items required

AG. Volkswagen AG d
agen oes
lksw not
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 by V with cable V.A.G 1551/3
o gu
ara
◆ Test box V.A.G 1598/18 rise
d
nte
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715 autho eo
ra
◆ Adapter set V.A.G 1594 ss c
◆ Current flow diagram

ce
e
nl

pt
du

◆ Chilling spray (commercially available)

an
itte

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erm

ab
Test sequence

ility
ot p

wit
, is n

- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
h re
hole

with the "Address word" 01.

(Connecting fault reader and selecting engine control unit => Page 2 .) spec
es, in part or in w

t to the co

-> Indicated on display:

Rapid data transfer HELP
rrectness of i

Select function XX
l purpos

- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.
nform
ercia

-> Indicated on display:

m

at

Read measured value block HELP

om

io

Input display group number XXX

n
c

in t
or

his
te

- Press keys 0, 0 and 2 for "Display group number 2" and confirm entry with Q key.
a

do
priv

cum
for

-> Indicated on display:

en
ng

t.
yi
(1...4 = Display zones)
Co
Cop py
t. rig
Read measured value block 2 gh ht
pyri by
1 2 3 4 co
by
Vo
lksw
cted agen
Prote AG.

52 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997
- Read off intake air temperature value in display zone 4.

Display Cause Continuation of

check
-40 °C Open circuit or => Page 53
short to positive
129 °C Short to earth => Page 54
Approx. ambient --- => Page 54
temperature1)
1) If a temperature is displayed which is below the ambient air temperature of the sender, check sender
wiring for transfer resistances. Note when doing this that sender is heated from external sources, e.g. radiated
heat when engine is not running.
Continuation of check when display -40 °C:

- -> Pull connector -1- off intake air temperature sender (G42) with intake manifold pressure sender (G71)
-2-.
- Bridge connector contacts 1+2 using aux. cables from V.A.G 1594 and observe display.
Volkswa n AG. gen AG
wage does
Display 129 ° C: Volks not
gu
by ara
ed nte
ris
- Press ⇒key. tho eo
- Press keys 0 and 6 for the function "End au
output"
ra
ss and confirm entry with the Q key. c
- Switch off ignition.

ce
le
un

pt
- Renew intake air temperature sender (G42) with intake manifold pressure sender -2-

an
d
itte

=>Page 30 , item 1 .

y li
rm

ab
pe

ility
Display -40 ° C:
ot

wit
, is n

h re
- Press ⇒key.
hole

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key. spec
es, in part or in w

- Switch off ignition. t to the co

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
op
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
C py
t. rig
gh
- Check wire between test box socket 43 and 4 pin connector contact 2 for open circuit according to current
ht
pyri by
Vo
flow diagram.
co lksw
by
cted agen
Prote AG.

2.8 - Checking intake air temperature sender 53

 1AV injection and ignition system - Edition 08.1997
Wire resistance: Max. 1.5 ω
- Check wiring additionally for short circuit to battery positive.
G. Volkswagen AG d
Specification: ∞ω lkswagen A oes
not
- Check wire between by test box socket 17 and 4 pin connector
Vo gu
ara contact 1 for open circuit according to current
flow diagram.orised
nte
Wire resistance:
au
th Max. 1.5 ω eo
ra
ss c

ce
e

If no fault in wire is detected:

nl

pt
du

an
- Renew engine electronics control unit => Page 63 .
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

io
Continuation of check when display 129 °C:
n
c

in t
or

his
e

- -> Pull connector -1- off intake air temperature sender (G42) with intake manifold pressure sender (G71)
at

do
riv

-2-.
p

cum
for

en
ng

Display -40 ° C:
t.
yi Co
Cop py
- Press ⇒key.
t. rig
gh ht
yri
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key. p by
o Vo
by c lksw
- Switch off ignition. Prote
cted agen
- Renew intake air temperature sender (G42) with intake manifold pressure sender -2-
AG.

=>Page 30 , item 1 .

Display 129 ° C:
- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Pull connector off engine control unit.
- Check wiring to control unit connector at 4 pin connector contact 2 for short to wire contact 1 and to vehicle
earth.
Specification: ∞ω

If no wiring fault is detected:

- Renew engine electronics control unit => Page 63 .

Continuation of check when display = ambient temperature:

54 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997
- -> Remove intake air temperature sender together with intake manifold pressure sender (connector remains
connected).
- Note intake air temperature value in display zone 4.
- Spray sender with commercial chilling agent whilst observing the temperature value. The temperature value
must
decrease.
- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

2.9 - Checking injectors

Checking activation
Special tools, testers, measuring instruments and auxiliary items required
◆ Test box V.A.G 1598/18
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Diode test lamp V.A.G 1527
◆ Adapter set V.A.G 1594
◆ Current flow diagram

Check conditions
• Hall sender in distributor must be OK.
• Fuel pump relay must be OK

Test sequence
- Remove air cleaner => Page 34 , Fig. 3 .

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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an

- -> Pull connector off injectors -arrows-.

itte

y li

- Connect diode test lamp V.A.G 1527 using aux. cables from V.A.G 1594 to connector contacts of Cyl. 1.
erm

ab

- Operate starter.
ility
ot p

The LED must flicker

wit
, is n

h re

- Repeat check at the injector connectors Cyl. 2...4.

hole

spec
es, in part or in w

The LED does not flicker on any cylinder:

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.8 - Checking intake air temperature sender 55
 1AV injection and ignition system - Edition 08.1997
- -> Connect diode test lamp to connector Cyl. 1, contact 1 and earth.
- Operate starter.
The LED must light up

If the LED does not light up:

- Check wire between 2 pin connector contact 1 and fuel pump relay (J17) for open circuit according to current
flow diagram.
Wire resistance: max. 1.5 ω

The LED flickers on one or several cylinders:

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Check wiring between test box and connectors of injectors for open circuit according to current flow diagram.
Cyl. 1 connector, contact 2+socket 7
Cyl. 2 connector, contact 2+socket 6
Cyl. 3 connector, contact 2+socket 28
Cyl. 4 connector, contact 2+socket 4
Wire resistance: Max. 1.5 ω
- Additionally check wires for short to one another.
Specification: ∞ω
- Check wiring between connector contacts 1 of injectors for open circuit.
Wire resistance: Max. 1.5 ω . Volkswag AG en AG
agen does
olksw not
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s au ra
c
s

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pt
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d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

- Additionally check wires for short to one another.

rrectne

Specification: ∞ω

Checking resistance of injectors with wiring

ss o
cial p

f in

- -> Check of resistance injectors between contacts.

form
mer

Specification: 14...17 ω
atio
om

Checking spray pattern and for leaks

c

i
or

n thi
te

sd
a

Special tools, testers, measuring instruments and auxiliary items required

iv

o
pr

cum
r
fo

en
ng

◆ Adapter set V.A.G 1594

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

56 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

◆ Digital potentiometer V.A.G 1630

t to the co
◆ Measuring unit V.A.G 1602

rrectne
Test sequence
- Pull 3 pin connector off ignition transformer.

ss
- -> Pull 4 pin connector -1- off coolant temperature sender (G62) -2-.

o
cial p

f
- Connect digital potentiometer V.A.G 1630 using aux. cables from V.A.G 1594 to connector contacts 1+3

inform
and set connected side to 15 kω.
mer

- Pull connector off throttle valve control part, oil pressure switch and intake manifold pressure sender, and

atio
m

unclip wiring at intake pipe and coolant regulator housing.

o

n
c

- Remove fuel manifold complete with all injectors from intake pipe (fuel hoses remain connected).

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- -> Hold a small container under the injector to be checked and pull connectors off all other injectors.
- Operate starter, using a 2nd person. Injector must spray pulsatingly.
- Repeat check with other injectors ensuring that injector to be checked is only connected.
- Switch off ignition and afterwards check injectors for leaks. No more than
2 drops/min
may leak from each injector.

Note:
When installing the injectors ensure that the O rings
are not damaged.

2.10 - Checking fuel pressure regulator and holding pressure

The fuel pressure regulator controls the fuel pressure dependent upon intake manifold pressure.
Special tools, testers, measuring instruments and auxiliary items required
◆ Pressure tester V.A.G 1318
◆ Adapter 1318/10
◆ Adapter 1318/11

2.9 - Checking injectors 57

 1AV injection and ignition system - Edition 08.1997
◆ Adapter 1318/16

Test conditions

• Fuel pump delivery rate OK, checking delivery rate:

=> Repair group 20; Removing and installing parts of the fuel supply system; Checking fuel pump Removing
and installing parts of the fuel supply system Checking fuel pump

Test sequence

Warning!
Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release
pressure by carefully loosening the connection.

- -> Pull the fuel supply hose (white marking) -1- off fuel supple pipe -2-.
- Connect pressure measured device V.A.G 1318 using adapter 1318/10 to hose and using adapters /11 and /
16 to fuel supply pipe. AG. Volkswagen AG d
agen
- Open measured device cut-off tap. (The handle points Volksw in throughflow direction
oes
n-arrow-).
ot g
- Start the engine and run at idling speed. ed by ua
ra
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nl

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itte

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erm

ab
ility
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, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i

- Measure fuel pressure.

l purpos

Specification: Approx. 2.5 bar

- -> Pull vacuum hose off fuel pressure regulator -1- at intake pipe -2-. The fuel pressure must
nform
ercia

increase
to approx. 3.0 bar.
m

at
om

- Switch off ignition.

ion
c

- Check for leaks and holding pressure by watching pressure drop on gauge. After 10 minutes there must be
in t
or

a residual pressure of
his
ate

do

at least 2 bar.
priv

cum
for

en
g

If the holding pressure drops below 2 bar:

n

t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

58 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

- Start the engine and run at idling speed.

- -> Switch ignition off after the pressure has built-up. At the same time close pressure measured device cut-
off tap (handle cross throughflow direction -arrow-).
- Observe pressure drop on gauge.

If the pressure does not drop: agen

AG. Volkswagen AG d
oes
olksw not
y V gu
b
- Check fuel pump non-returnrisvalve.
ed ara
nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

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, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

=> Repair group 20; Removing and installing parts of the fuel supply system; Checking fuel pump non-return
valve. Removing and installing parts of the fuel supply system Checking fuel pump non-return valve.
nform
mercia

at

If the pressure drops again:

om

ion
c

in t
or

- -> Open pressure tester V.A.G 1318 shut-off tap (handle in throughflow direction -arrow-).
his
ate

- Start the engine and run at idling speed.

do
priv

- Switch ignition off after the pressure has build-up. At the same time pinch/seal the return hose (with blue
um
for

marking) -3- together.

en
ng

t.
yi Co
Cop py
t. rig
If the pressure does not drop: opyri
gh by
Vo
ht
c by lksw
cted
- Renew fuel pressure regulator
agen
Prote AG.
=>Page 29 , item 4 .

If the pressure drops again:

- Check pipe connections, O-rings on fuel manifold and injectors for leaks.
- Check pressure gauge for leaks.

Note:

Before removing pressure gauge place a cloth around the connections to be loosened.

2.10 - Checking fuel pressure regulator and holding pressure 59

 1AV injection and ignition system - Edition 08.1997

2.11 - Checking intake air system for leaks (unmetered air)

Special tools, testers, measuring instruments and auxiliary items required

AG. Volkswagen AG d
agen oes
ksw
◆ Fault reader V.A.G 1551 or vehicle by system tester V.A.G 1552 withgcable
Vol not
ua V.A.G 1551/3
◆ Engine leak detector spray Gris001
ed 800 A1 ran
te
tho eo
au ra
Test sequence ss c

ce
e
nl

pt
du

Notes:

an
itte

y li
erm

ab
◆ The vacuum in the intake system will cause the leak detector spray to be drawn in with the unmetered air.

ility
ot p

The leak detector spray reduces the ignitability of the mixture. This leads to a drop in engine speed and to

wit
, is n

a change of Lambda probe reading.

h re
hole

◆ The safety precautions listed on the container must be adhered to.

spec
es, in part or in w

t to the co
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

rrectness of i
-> Indicated on display:
l purpos

Rapid data transfer HELP

Select function XX

nform
ercia

- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.
m

at
om

ion
c

in t
-> Indicated on display:
or

his
ate

Read measured value block HELP

do
priv

c
Input display group number XXX
um
for

en
ng

t.
yi Co
- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key. t. Cop py
rig
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yri by
-> Indicated on display:
op Vo
by c lksw
(1...4 = Display zones) cted agen
Prote AG.
Read measured value block 1
1 2 3 4

- Note engine speed in display zone 1.

- Note Lambda probe voltage in display zone 3 and the area it fluctuates in.
- Systematically spray parts of the intake system with engine leak detector spray.

Engine speed or Lambda probe voltage does not change:

- Press the ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

If the engine speed drops or the Lambda probe voltage changes:

- Press the ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Check sprayed areas of intake system for leaks and rectify if necessary.

2.12 - Checking intake air preheating

Checking regulating flap

- Remove air cleaner intake support.

60 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

- -> Check control flap position -1-.

- Above +23 °C flap must close warm air connection
- Below +10 °C flap opens warm air connection

Note:
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The function of the thermo by V element -2- can be checkedt geasily
olk o
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2.12 - Checking intake air preheating 61

 1AV injection and ignition system - Edition 08.1997

2.13 - Wire routing engine wiring loom

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1 Coolant temperature sender (G62)
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2 Central connector
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3 Push-in clip
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5 Throttle valve control part (J338)
6 Cable guide
7 Injectors (N30...N33)
8 Oil pressure switch (F22)

62 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

AG. Volkswagen AG d
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9 Intake manifold pressure sender (G71) with intake air temperature sender (G42)
o

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10 Knock sensor 1 (G61)

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1 Earth connection
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◆ Engine earth
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2 Hall sender (G40)

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3 - Replacing and matching engine control unit
Prote AG.

3.1 - Replacing and matching engine control unit

3.2 - Replacing engine control unit

The engine control unit regulates the injection, throttle valve control part, Lambda control, ignition, knock control,
activated charcoal filter solenoid valve 1, governed speed via injectors as well as self-diagnosis

2.13 - Wire routing engine wiring loom 63

 1AV injection and ignition system - Edition 08.1997
Conditions

• Ignition switched off

Work sequence

- Remove plenum chamber cover, left.

- Release the control unit connector and pull connector off. G. Volkswagen
- Remove the control unit complete with securing plate.
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- Replace the control unit. y Vol ot g
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Installation is carried out in reverse order to
au removal.
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Then: or
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- Perform basic setting => Page 64 .
un

pt
an
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- Match new control unit to the electronic immobilizer => Page 65

itte

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- Then subsequently interrogate the fault memory of the new engine control unit and erase the fault memory
rm

ab
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if necessary.

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3.3 - Performing basic setting
es, in part or in w

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Note:

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The basic setting with the ignition switched on, matches the engine control unit to the throttle valve control part.
l purpos

Special tools, testers, measuring instruments and auxiliary items required

nform
ercia

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
m

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tion in
Test conditions
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• No faults must be stored in fault memory

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=> Page 6 , interrogating fault memory

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Test sequence
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- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
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with the "Address word" 01.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 0 and 4 for the function "Introduction of basic setting" and confirm entry with Q key.

-> Indicated on display:

Basic setting HELP
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
System in basic setting 1
1 2 3 4

After pressing the Q key, the throttle valve positioner will be moved to the min., max. and three intermediate
positions and the control unit will store each individual throttle valve angle in the non-volatile memory. This
procedure lasts approx. 10 seconds. The throttle valve will then remain in the start position.

64 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997
Note:
If the basic setting of the control unit is interrupted, theagcause
en AG. Vcouldagbe
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◆ Throttle valve cannot reach the mechanical d bstop because of contamination e.g.uoil
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ise nte
adjusted throttle cable. hor eo
◆ Battery voltage too low. aut ra
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◆ Throttle valve control unit or wirings is defective. Checking => Page 41 .

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After an interruption the fault "Basic setting not completed, fault in basic setting" is stored in fault memory. When

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next switching on ignition the basic setting is automatically performed again.

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- End the engine basic setting by pressing the⇒ key.
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- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
hole

spec
es, in part or in w

If the throttle valve positioner does not move:

t to the co
- Observe 8 digit number block in display zone 4. The 2nd, 3rd and 5th position from right must be at 0.
Display: 00000000

rrectness of i
Note:
l purpos

If in display zone 4 a 1 is displayed in the mentioned positions then test prerequisites are not fulfilled:

nform
ercia

=>Page 17 ; Significance of figures in 8 digit number block

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ion
All positions at 0:
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- Check throttle valve control part

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=> Page 41 .

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3.4 - Matching engine control unit to electronic immobilizer pyri by
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Special tools, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3

Test conditions
• Authorized vehicle key required.

Work sequence

- -> Fold driver's side stowage compartment down.

- Connect fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3.
- Switch on ignition.
- Operate fault reader or vehicle system tester taking into account the information on the display:
- Press key 1 for "Rapid data transfer".
- Press keys 2 and 5 for address word "Immobilizer" and confirm entry with Q key.

3.3 - Performing basic setting 65

 1AV injection and ignition system - Edition 08.1997
- After the immobilizer control unit has registered, press ⇒ key.

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 1 and 0 for function "Adaption" and confirm entry with Q key.

-> Indicated on display:

Adaption
Feed in channel number XX

- Press key 0 twice for "Channel number 0" and confirm entry with Q key.

-> Indicated on display:

Adaption Q
Erase learnt values?

- Confirm input with Q key.

-> Indicated on display:

Adaption
Learnt values have been erased

- Conclude adaption by pressing ⇒ key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition

Note:
The identity of the engine control unit is read into the immobilizer control unit when next switching the ignition
on.

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aut items required
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◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
un

◆ Test box V.A.G 1598/18 pt

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◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715 y li

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◆ Adapter set V.A.G 1594 ility
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◆ Current flow diagram

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Check conditions
spec
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t to the co

• Battery voltage at least 11 V.

• Alternator must be OK
rrectne

Test sequence
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
ss

unit. When doing this the engine must be running at idling speed.
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cial p

(Connecting fault reader and selecting engine control unit => Page 2 .)
inform
mer

atio

-> Indicated on display:

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66 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

Read measured value block HELP

Input display group number XXX

- Press keys 0, 0 and 2 for "Display group number 2" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 2
1 2 3 4

- Read off display values in display zone 3.

Specification: constantly approx. battery voltage
- Press ⇒key. gen AG
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If the displayed figure fluctuates or the battery voltage is not attained:

- Switch off ignition.

nf
ercia

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

orm
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atio
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- Measure supply voltage between test box sockets 1+21 using multimeter and adapter cables from V.A.G
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1594:
or

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Specification: at least 11 V
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- Measure supply voltage between test box sockets 1+23 using multimeter and adapter cables from V.A.G
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- Check wiring connections according to relay plate according to current flow diagram.

4 - Checking additional signals

4.1 - Checking additional signals

4.2 - Testing speed signal

Special tools, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Test box V.A.G 1598/18
◆ Adapter set V.A.G 1594

3.5 - Checking control unit voltage supply 67

 1AV injection and ignition system - Edition 08.1997
◆ Current flow diagram

Test conditions

• Speedometer must be OK., checking speedometer:

=> Repair group 90; Electrical system Electrical system

Test sequence

Note:

To check the speed signal the vehicle must be driven. To do this a second person is necessary.

Warning!
Secure fault reader to rear seat and operate from this position.

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

lksw
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wag"Display
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- Carry out test drive and when doing use a 2nd person to observe display.
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- Drive off slowly. The displayed value must decrease.

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- Press the ⇒key.

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- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
spec
es, in part or in w

t to the co

If the display does not change:

- Switch off ignition.

rrectness of i
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68 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Set multimeter scale to measure voltage and connect between test box sockets 1+36.
- Switch on ignition.
- Lift front left-hand wheel.
- Rotate front wheel and observe voltage display.
Specification: between 0 and at least 4 Volt fluctuating

If the display does not fluctuate:

- Check wiring to speedometer or to speedometer sender.

=> Current flow diagrams, Electrical fault finding and Fitting locations binder
AG. Volkswagen A
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4.3 -auChecking air conditioner and air conditioner compressor signals
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These signals from the air conditioner cause the initial control value for the idling stabilization to be increased
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when the air conditioner compressor switches in. Thereby the idling stabilization remains in the middle of the

ab
pe

ility
regulating range.
ot

wit
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Special tools, testers, measuring instruments and auxiliary items required
hole

spec
es, in part or in w

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3

t to the co
◆ Test box V.A.G 1598/18
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Adapter set V.A.G 1594 rrectness of i
◆ Current flow diagram
l purpos

Test conditions
nform
ercia

• Air conditioner functioning OK.

• Air conditioner must be switched off
m

a
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• No faults must be stored in fault memory

ion in

=> Page 6 , interrogating fault memory

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te o

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• Vehicle at room temperature (warmer than + 15 °C).

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Test sequence
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- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
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unit. When doing this the engine must be running at idling speed.
yri
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(Connecting fault reader and selecting engine control unit => Page 2 .)
c by lksw
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-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 1
1 2 3 4

- Observe 8 digit number block in display zone 4. 3rd position from left must display 0.
Display: 00000000

4.2 - Testing speed signal 69

 1AV injection and ignition system - Edition 08.1997
- Switch on air conditioner. Adjust lowest temperature and highest blower stage.

3rd position from left must now display 1

Display: 00100000

If the display does not change:

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- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

h re
ole,

- Check wiring between test box sockets 33 and 35 and the air conditioner for open circuit according to current

spec
flow diagram.
urposes, in part or in wh

Wire resistance: Max. 1.5 ω

t to the co
rrectness o
cial p

f inform
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70 24 - Mixture preparation, Injection

 1AV injection and ignition system - Edition 08.1997

28 - Ignition system

1 - Servicing ignition system

1.1 - Servicing ignition system

1.2 - General notes on ignition system

◆ Only the components which specifically relate to the ignition system are dealt with here. For the other com‐
ponents of the injection and ignition system => Repair group 24.
◆ Disconnecting and connecting the battery must only be done with the ignition switched off, otherwise the
engine control unit could be damaged.
◆ The engine control unit is equipped with self diagnosis.
◆ Components marked with * are checked via the self diagnosis.
=> Page 6 , interrogating fault memory
◆ For trouble-free operation of the electrical components a voltage of at least 11.5 V is necessary.
◆ During some checks it is possible that the control unit will recognise and store a fault. Therefore after com‐
pleting all checks and repairs G. Volkmemory
swagen AG
swagthe
en Afault must
does be interrogated and if necessary erased.
=> Page 6 , interrogating
by Vol and erasing fault memory ot gu
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Safety precautions au
t=> Page
ho
76 e or
ac
ss
ce
le

Test data, spark plugs => Page 76

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urposes, in part or in wh

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1.1 - Servicing ignition system 71

 1AV injection and ignition system - Edition 08.1997

1.3 - Removing and installing parts of the ignition system

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1 Earth strap atio

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2 Connector
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3 10 Nm
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4 Ignition transformer (N152)

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◆ With output stage (N157)

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◆ Checking => Page 79
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5 Suppressor
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◆ 0.6...1.4 kω
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6 Screening cap
Prote AG.

7 Distributor cap
◆ Check for cracks and signs of tracking
◆ Check contact wear
◆ Clean before fitting
◆ Check carbon brush for wear and freedom of movement

72 28 - Ignition system
 1AV injection and ignition system - Edition 08.1997

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8 Rotor arm
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◆ Marking: R1
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◆ 0.6...1.4 kω
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9 Dust cap
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10 No. 1 Cyl. marking py by
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◆ Dismantling and assembling => Page 75
◆ Checking and adjusting ignition timing => Page 76
◆ Checking Hall sender
=> Page 78
12 O ring
◆ Renew if damaged
13 20 Nm
◆ Tightening torque influences the function of the knock sensor

1.3 - Removing and installing parts of the ignition system 73

 1AV injection and ignition system - Edition 08.1997

AG. Volkswagen AG d
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14 Knock sensor 1 (G61)*

◆ Sensor and connector contacts are gold-plated
15 Spark plug, 25 Nm
◆ Type and electrode gap
=> Page 76
16 Spark plug connector
◆ 4...6 kω
17 H.T. cable
◆ Check for continuity

74 28 - Ignition system
 1AV injection and ignition system - Edition 08.1997

1.4 - Dismantling and assembling distributor

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1 Distributor shaft h re
hole

◆ With Hall sender rotor

spec

◆ Pull out after removing the spring pin -7-

es, in part or in w

t to the co

2 O ring
◆ Renew if damaged
3 3 Nm
rrectness of i

4 Plastic washer
l purpos

5 Shim(s)
6 Hall sender (G40)
nform
ercia

◆ Checking => Page 78

m

7 Distributor body
at
om

io

8 Spring pin
n
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9 Coupling
at

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◆ Before removing mark position of drive tongue to shaft - 1 -

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1.4 - Dismantling and assembling distributor 75

 1AV injection and ignition system - Edition 08.1997

1.5 - Safety precautions

To prevent injuries to persons and/or damage to the injection and ignition system, the following must be ob‐
served:
n AG. Volkswagen A
◆ Do not touch or pull off ignition wiring when engine olks
wais
ge running or turning
G do
at
es nstarter speed.
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◆ The ignition must be switched off when disconnecting
d by V or connecting injection and
ua ignition system wiring as
ran
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◆ If the engine is to be turned at starterauspeed, without starting, e.g. when checking compressions,
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off Hall sender (distributor). ss

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◆ Do not connect a capacitor to terminal 1 (-). le
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◆ Do not replace 1 kω (identification: R1) with a different type even for radio interference suppression.

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◆ For suppression purposes only 1 kω resistances are to be used on the H.T. leads and 5 kω spark plug
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connectors.

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1.6 - Adjustment data, Spark plugs
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Engine code AEE, ALM
Ignition timing1)

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Test value 3...8 °BTDC

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Adjusting value 6±1 °BTDC

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Speed 1150...1400 rpm2)

inform
Ignition timing 1-3-4-2
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Spark plugs1)
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VW/Audi 101 000 036AA;
or

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101 000 050AC;

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101 000 040AD

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Manufacturer's designation BUR6ET;

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W7LTCR;
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14GH-7DTUR
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Electrode gap BUR6ET,
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0.7...0.9 mm
W7LTCR:
0.9...1.1 mm
Tightening torque 25 Nm

1) The up-to-date figures and the spark plug change intervals:

=> Exhaust emissions test binder

2) The rpm is increased by the engine control unit in "04 basic setting" function.

1.7 - Checking and adjusting ignition timing

Special tools, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
◆ Ignition tester V.A.G 1767 or V.A.G 1367 with HT pick-up clamp V.A.G 1367/8

Check conditions

• Coolant temperature at least 80 °C

• No faults must be stored in fault memory

76 28 - Ignition system
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s 1AV injection and ignition system - Edition 08.1997

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=> Page 6 , interrogating fault memory
itte

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Test sequence
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t to the co
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- -> Connect ignition tester V.A.G 1767 or ignition tester V.A.G 1367 with HT pick-up clamp V.A.G 1367/8.
t

sd
va

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
i

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unit. When doing this the engine must be running at idling speed.
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(Connecting fault reader and selecting engine control unit => Page 2 .)
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Select function XX Prote AG.

- Press keys 0 and 4 for the function "Introduction of basic setting" and confirm entry with Q key.

-> Indicated on display:

Basic setting HELP
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
System in basic setting 1
1 2 3 4

Do not continue with check until an 8 digit number block 00000000 appears in the 4th display zone.

Note:

If at one or more positions a 1 is displayed in display zone 4, the test conditions have not been fulfilled:

=>Page 17 ; Relevance of figures in 8 digit number block

- The engine control unit increases the idling speed to 1150...1400 rpm.
- Check ignition timing.
Specification: 3...8 ° before TDC1)
- Adjust ignition timing by turning distributor, if necessary.
Adjustment figure: 6±1 ° before TDC1)

1) Up-to-date specifications:

=> Exhaust emissions test binder

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Check basic setting, if necessary.
=> Page 64 .

1.7 - Checking and adjusting ignition timing 77

 1AV injection and ignition system - Edition 08.1997

1.8 - Checking Hall sender

Special tools, testers, measuring instruments and auxiliary items required

◆ Test box V.A.G 1598/18

◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Adapter set V.A.G 1594
◆ Current flow diagram

Test conditions

• If a fault on Hall sender is recognised by self diagnosis.

Test sequence

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- Pull connector off Hall sender
horis
(distributor). nte
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- -> Connect multimeter autto measure voltage using aux. cables from V.A.G ra 1594 to the outer contacts of the
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connector. s
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- Switch on ignition.
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Specification: min. 9 V
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- Switch off ignition.

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- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
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- Check wiring between test box and connector for open circuit according to current flow diagram.
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Contact 1+socket 17
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Contact 2+socket 13
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Contact 3+socket 8
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Wire resistance: Max. 1.5 ω Cop py
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- Additionally check wires for short to one another. yri
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Specification: ∞ω
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If no wiring fault is detected and voltage was present between contacts 1+3:

- Renew Hall sender => Page 75 , item 6 .

78 28 - Ignition system
 1AV injection and ignition system - Edition 08.1997
If no wiring fault is detected and no voltage was present between contacts 1+3:

- Renew engine electronics control unit => Page 63 .

1.9 - Checking ignition transformer and output stage

Special tools, testers, measuring instruments and auxiliary items required

◆ Test box V.A.G 1598/18

◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Adapter set V.A.G 1594
◆ Diode test lamp V.A.G 1527
◆ Current flow diagram

Check conditions

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Checking ignition transformer au or
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- Pull connector and H.T. cable off ignition transformer (N152).

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- -> Check primary resistance between terminals 1 and 15.

itte

Specification: 0.5...1.5 ω y li
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- Check secondary resistance between terminals 4 and 15. ility
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Specification: 2.5...4 kω wit

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If the specifications are not attained:

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- Replace ignition transformer => Page 72 , item 4 .

Checking voltage supply

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- Pull 3 pin connector off ignition transformer.

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1.8 - Checking Hall sender 79

 1AV injection and ignition system - Edition 08.1997
- -> Connect multimeter to measure voltage with aux. cables from V.A.G 1594 to the contacts 1+3 of the
disconnected plug.
- Switch ignition on.
Specification: at least 11 V

If no voltage is present:

- Switch off ignition

- Check wire between 3 pin connector contact 1 and earth for open circuit according to current flow diagram.
Wire resistance: Max. 1.5 ω
- Check wire between 3 pin connector contact 3 and relay plate for open circuit according to current flow
diagram.
Wire resistance: Max. 1.5 ω

Checking activation

- Pull connector off injectors.

- -> Connect diode test lamp V.A.G 1527 with aux. cables from V.A.G 1594 and adapters V.A.G 1594/15 to
contacts 2+3 of the plug. agen AG. Volkswagen AG do
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LED must flicker rised ran
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- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
nf
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- Check wire between test box socket 24 and 3 pin connector contact 2 for open circuit according to current
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flow diagram.
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Wire resistance: Max. 1.5 ω

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- Additionally check wires for short to one another.

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Specification: ∞ω
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If no wiring fault is detected and voltage was present between contacts 1+3:
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- Renew engine electronics control unit => Page 63 .
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If the voltage supply and activation is OK.:
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80 28 - Ignition system
 1AV injection and ignition system - Edition 08.1997
- Connect 3 pin connector and H.T. cable to ignition transformer.

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- -> Connect diode test lamp using aux. cables and clamps to the contacts 1 and 15 on ignition transformer.
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Warning!

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During the following test do not touch the terminals of the ignition transformer or test cables.

- Operate starter.

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The LED must flicker

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1.10 - Checking knock sensor form
mer

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Special tools, testers, measuring instruments and auxiliary items required

thi
te

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◆ Test box V.A.G 1598/18

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◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715

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◆ Adapter set V.A.G 1594
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Test conditions
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• Self-diagnosis has recognized a fault on knock sensor.

Test sequence

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Check wiring and knock sensor for short circuit.
Sockets: 19+39, 39+45, 19+45
Specification: ∞ω

If no short is detected:

1.9 - Checking ignition transformer and output stage 81

 1AV injection and ignition system - Edition 08.1997

AG. Volkswagen AG d
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- -> Pull connector -1- off knock sensor 1 (G61) -2-. d by V gu
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- Check wiring between test box and knock sensor orisfor open circuit according to current flowandiagram.
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tee
Contact 1+socket 39 aut
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Contact 2+socket 19 ss

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Wire resistance: Max. 1.5 ω

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pt
- Measure resistance between knock sensor contacts.

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Specification ∞ω
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If no wiring fault is detected:

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is n

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ole,

- Loosen knock sensor and tighten again to 20 Nm.

spec
urposes, in part or in wh

- Carry out test drive.

t to the co
During the road test the following operating conditions must be fulfilled:
- The coolant temperature must exceed 80 °C .

rrectne
- When the temperature is reached, the operating conditions
Idling
Part throttle

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Full throttle
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Overrun

form
mer

must be attained several times.

atio
- At full throttle the speed must exceed 3500 rpm.
om

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- Again interrogate the control unit fault memory.

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If the fault is still present: um
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- Replace knock sensor C py
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=>Page 74 , item 14 .
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82 28 - Ignition system