Servicing injection system: VW 2.3 (AGZ)

Servicing ignition part

=> Repair group 28
Motronic injection and ignition system (5-cyl.)

Notes:

The control unit for the fuel injection and ignition system is equipped with a fault memory. Before carrying out repairs, adjustment work and fault finding the fault memory must be interrogated and the vacuum connections checked (outside air).
Components marked with * are checked via the self diagnosis.
=> Page
01-7
, interrogating fault memory
Components marked with ** are checked via the final control control diagnosis => Page
01-85
.
For trouble-free operation of the electrical components, a voltage of at least 11.5 V is necessary.
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.
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 be interrogated and if necessary the control unit matched => Page
24-110
.
During some checks it can happen that the control unit will recognise and store a fault. Therefore after completing all checks and repairs the fault memory must be interrogated and if necessary erased.
=> Page
01-7
, interrogating fault memory

Safety precautions =>Page
24-26

Rules for cleanliness => Page
24-27

Technical data => Page
24-28

Checking engine operation => Page
24-43

Air cleaner
Dismantling and assembling => Page
24-23

Activated charcoal filter solenoid valve 1 (N80)
Activated charcoal filter system

=> Repair group 20; Removing and installing parts of the fuel supply system; Servicing parts of the activated charcoal filter system
Motronic injection and ignition system (5-cyl.)
Removing and installing parts of the fuel supply system
Servicing parts of the activated charcoal filter system

Air mass meter (G70)*
Checking => Page
24-46

Intake hose
Ensure seated tightly
With connection to intake manifold lower part => Page
24-21
item
5
Observe assembly markings

Throttle valve control part (J338)*
Checking => Page
24-52

Crankcase breather valve
Installation position => Page
24-25
Fig.
1

To cylinder head cover
Securing plate
For engine control unit

Motronic injection and ignition system control unit (J220)
Fitting location: In protective housing, plenum chamber, left
For injection system, throttle valve control part, Lambda regulation, idling speed control, knock control, activated charcoal filter solenoid valve 1, speed governing via injectors or fuel pump relay, ignition and self diagnosis
Voltage supply via terminal 15 and terminal 30
Checking voltage supply => Page
24-77
Renew => Page
24-100

Connector, 52 pin
For engine control unit
Only disconnect or connect with ignition switched off
Release to disconnect

Connector, 28 pin
For engine control unit
Only disconnect or connect with ignition switched off
Release to disconnect

Coolant temperature sender (G62)*
Blue, with temperature gauge sender (G2)
For engine control unit
Checking => Page
24-64
If necessary release pressure in cooling system before removing

Intake manifold upper part
With twin path intake manifold change-over => Page
24-11

Gasket for intake manifold lower part
Renew

Fuel rail
Dismantling and assembling => Page
24-21

Intake manifold - lower part
Engine speed sender (G28)*
Fitting location: cylinder block intake side
Checking wiring to engine speed sender => Page
24-75

Intake manifold temperature sender (G72)*, 15 Nm
Lambda probe (G39)*, 50 Nm
Fitting location: front 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
24-32
Probe heating voltage supply via fuel pump relay (J17)
Checking Lambda probe heating => Page
24-40

Air duct
From activated charcoal filter container