VW Golf 3 2e Digifant Injection Ignition Eng
VW Golf 3 2e Digifant Injection Ignition Eng
VW Golf 3 2e Digifant Injection Ignition Eng
Edition 04.1993
Repair Group
01 - Self diagnosis, Electrical check
24 - Mixture preparation, Injection
28 - Ignition system
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.
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
Contents
Contents i
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
ii Contents
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
1 - Self diagnosis
1.1 - Self diagnosis
1.2 - Function
The Digifant control unit (J169) for the injection and ignition system 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.
The stored faults are output after initiating the fault display => Page 3 .
This fault memory must be erased once the faults have been eliminated => Page 3 .
Faults like an intermittent open circuit or loose contact, are stored and displayed as follows:
◆ If the faults occur for max. 5 seconds, they will be stored as sporadic faults and as such indicated with the
addendum "SP".
◆ If the faults occur for longer than 5 seconds, they will be stored as faults and displayed, even though the
faults may not be present at that time.
A fault relating to the function of the Lambda control system can only be interrogated after a test drive of at
least 5 minutes duration.
Equipped with
◆ Fault memory: Non-volatile memory
◆ Rapid data transfer
Selectable functions
1) The displayed figures in this function also the measuring value blocks required are described in the
respective repair procedures.
1.4 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit
Vehicles ▸07.93
- -> Unclip covers for diagnostic connections below the heating/ventilation controls.
- Connect fault reader V.A.G 1551 with cable V.A.G 1551/1 as follows:
- First connect black plug for the fault reader voltage supply to black diagnostic socket.
* Appears alternately
Note:
If the display remains blank:
=> Fault reader operating instructions
- Connect white plug to white diagnostic socket. (The blue plug is not required.)
Vehicles 08.93 ▸
-> The fault reader V.A.G 1551 display will show the control unit identification, e.g.:
037906024D DIGIFANT 1.7 1390
Coding
◆ 037 906 024D = Part No. of the control unit (for up-to-date control unit versions see parts catalogue)
◆ DIGIFANT = Injection system (Digifant)
◆ 1.7 = hardware version (build level) of control unit
◆ 1390 = software version (programme level number) of control unit
◆ Coding = Not used at present
- Press ⇒ key.
- Switch on ignition.
If no fault is stored:
- Press ⇒ key.
1.4 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit 3
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
X Faults recognised!
Note:
If something different is indicated on the display:
=> Fault reader operating instructions
The faults stored will be displayed and printed out one after the other.
Then the display will show:
- Press ⇒ key.
Note:
If a fault is present which is not recognised by the self diagnosis, carry out further fault finding using the fault
table in "Engine fault finding" binder.
Notes:
◆ The fault table is listed according to the 5 digit fault code on the left.
- Connect fault reader V.A.G 1551 and select engine electronics control unit (address word 01); carry out
selection with ignition switched on.
=> Page 2
- Operate fault reader taking into account the information on the display:
- Input 03 for "Final control diagnosis" function.
Note:
If something different is indicated on the display:
=> Fault reader operating instructions
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 ⇒button.
During the activation of the fuel pump relay the fuel pump must be heard to run at intervals.
=> Current flow diagrams, Electrical fault finding and Fitting locations; Fuel supply.
- Press ⇒key.
- -> Pull plug -1- off valve -2- and connect measuring cable V.A.G 1501 to valve and wiring loom.
- Connect diode test lamp V.A.G 1527 with adapters from V.A.G 1594 to connectors 1 and 3 of the measuring
cable.
LED must flash
- Press ⇒ button.
- Press ⇒ button.
Notes:
◆ If ignition is not switched off before trying to start engine, engine will not start as the injectors and ignition
transformer will not have been activated.
◆ If final control diagnosis has to be repeated, switch off ignition, disconnect lead from fault reader for at least
3 minutes, re-connect and carry out final control diagnosis.
- -> Pull plug off valve and connect diode test lamp V.A.G 1527 with aux. cables from V.A.G 1594 to discon‐
nected plug.
The LED must flash
LED flashes:
- Press ⇒ button.
2 - Electrical check
2.1 - Electrical check
2.2 - Wiring and component check with test box V.A.G 1598/18
Notes:
◆ Use the hand multimeter V.A.G 1526 or the multimeter V.A.G 1715 and the diode test lamp V.A.G 1527 for
the checks.
◆ The specifications given are valid for an ambient temperature from 0 to + 40 °C.
◆ If the measured figures deviate from the specifications, determine fault using current flow diagram.
◆ If the measured figures only deviate slightly from the specifications, clean sockets and plugs on the tester
and measuring cables, then repeat check. Before replacing components check wiring and connections and
particularly in cases of specifications less than 10ω repeat the resistance measurement on the component.
◆ To connect the testers to the test box use aux. cables from adapter set V.A.G 1594.
◆ The contact numbers of the plugs and the socket numbers in the test box are identical.
◆ Additional to the checks described in the table, if necessary, the wiring must also be checked for short to
earth (-) or battery positive (+).
- -> With ignition switched off pull connector -1- off control unit -2-.
- Connect test box to wiring loom connector.
- Carry out checks as per table => Page 9 .
Attention!
To prevent damage to the electronic components, switch to the respective measuring range before connecting
the measuring cable, observe the test conditions and carry out the additional work listed in the table.
Note:
After completing the electrical check, on vehicles with automatic gearbox, the fault "Engine/gearbox electrical
connection: open circuit"caused by the check and stored in the automatic gearbox control unit must be erased.
Test table
Test step Item checked ▪ Test conditions Test box sockets Specifications1)
- additional work
1 Voltage supply for Digifant control - Switch on ignition 1+8
unit (J169)
1 + 23
- Only vehicles ▸11.91 1 + 38
▪ Ignition switched on
2 Wire to ignition trans. (N152) ▪ Ignition switched on 1+7 app. battery voltage
32) Cold start valve (N17) ▪ Ignition switched on 6+1 app. battery voltage
4 Idling stabilization valve ▪ Ignition switched on 30 + 1 app. battery voltage
(N71)
5 Activated charcoal filter solenoid ▪ Ignition switched on 33 + 1 app. battery voltage
valve 1 (N80)
2) If the self diagnosis indicates a sender fault which is not established by this test, it could be caused by a
temporary break in the temperature signal. In this case, additionally check the coolant temperature sender =>
Page 42 .
2.2 - Wiring and component check with test box V.A.G 1598/18 11
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
Test step Item checked ▪ Test conditions Test box sockets Specifications1)
- additional work
17 Wire to white diagnostic socket - Vehicles ▸07.93 43 + Max. 1.5 ω
Contact 2 on white
diagnostic socket (upper)
- Vehicles 08.93 ▸ 43 + Contact 7 on diagnostic
socket
=>Fig. 2
2.2 - Wiring and component check with test box V.A.G 1598/18 13
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
=> Repair group 20, removing and installing parts of the fuel supply system, removing and installing parts of
the activated charcoal filter system
A- => Page 27
1 Filter element
2 Air cleaner upper part
3 Air ducting
4 5 Nm
5 Seal
◆ Renew if damaged
6 Connector
12 Temperature regulator
◆ For intake air preheating
◆ Installation position: brass hose connection at bottom
◆ Checking intake air preheating =>Page 56
13 Retaining ring
14 Packing
15 Air ducting
16 Air cleaner lower part
17 Vacuum unit
◆ Checking intake air preheating =>Page 56
Removing and installing throttle valve housing, cold start valve and idling stabilization valve
B - => Page 27
C - To activated charcoal filter solenoid valve 1 (N80)
◆ => Page 58 , vacuum hose connection diagram
D - => Page 27
E - => Page 27
1 Intake hose
3 O ring
◆ Renew if damaged
4 Connector
5 Throttle valve potentiometer (G69)*
◆ 3-pin connector for injection and ignition system
◆ 4-pin connector additional on vehicles with automatic gearbox to control unit for automatic gearbox (J217)
◆ Checking => Page 40
◆ After renewing:
Match Digifant control unit to engine by completing idling check
=> Page 42
6 Bolt
◆ Secure with plate or fluid
7 Seal
◆ Renew
8 Intake manifold
9 To activated charcoal filter solenoid valve 1 (N80)
◆ => Page 58 , vacuum hose connection diagram
10 Plug
11 CO take-off pipe
12 10 Nm
13 Connecting hose
◆ On vehicles with ABS
14 Non-return valve
Volkswagen Technical Site: http://vwts.ru http://vwts.info
=> Repair Group 19; removing and installing parts of cooling system; checking radiator fan run-on removing
and installing parts of cooling system checking radiator fan run-on
21 Support bracket
22 M6 = 10 Nm
M8 = 20 Nm
23 Idling speed stabilization valve (N71)**
◆ Resistance: 2...10 ω
A- => Page 18
B- => Page 21
D- => Page 21
E- => Page 21
1 Connecting hose
◆ To crankcase breather
2 Crankcase breather pressure regulating valve
3 Bracket
4 Warm air collector plate
5 25 Nm
6 20 Nm
7 Return pipe
◆ Blue or blue markings
8 Retaining clip
9 Supply pipe
◆ Black or white markings
10 O ring
◆ Renew if damaged
11 Fuel pressure regulator
◆ Checking fuel pressure regulator and holding pressure => Page 48
12 Seal
◆ Renew if damaged
13 Fuel manifold upper part
◆ Removing and installing:
=> Page 52 , removing and installing injectors
14 10 Nm
15 Injectors (N30...N33)
◆ Removing and installing
=> Page 52
◆ Checking => Page 53
16 Fuel rail
◆ Removing and installing:
=> Page 52 , removing and installing injectors
17 Intake manifold
18 Seal
◆ Renew
Removing and installing control unit, Lambda probe and coolant temperature sender
1 Connector
◆ Only disconnect or connect with ignition switched off
2 Digifant control unit (J169)*
◆ For injection system, Lambda regulation, engine speed governor via fuel pump relay, ignition and self
diagnosis
◆ After renewal:
Match Digifant control unit to engine by completing idling check => Page 33
3 Bracket
4 10 Nm
5 Connector
◆ For Lambda probe and Lambda probe heating
◆ Check Lambda probe heating voltage supply between contacts -1- and -2- with engine running:
Specification:
approx. battery voltage
◆ Check Lambda probe heating at Lambda probe connector (white wiring) for continuity
◆ Contact 3 - Lambda probe screening
◆ Contact 4 - Lambda control
7 Retaining clip
8 Connection
9 O ring
◆ Renew if damaged
10 Coolant temperature sender (G62)*
◆ With coolant temperature indicator sender (G2)
◆ If necessary before removing, release pressure from cooling system
◆ Resistance values
=> Page 12 , Fig. 1
11 Connector
To prevent injuries to persons and/or damage to the injection and ignition system, the following must be ob‐
served:
◆ Do not touch or pull off ignition wiring when engine is running or turning at starter speed.
◆ The ignition must be switched off when disconnecting or connecting injection and ignition system wiring as
well as test instrument cables.
When working on the fuel supply/injection system, pay careful attention to the following "5 rules":
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ 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.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
Engine code 2E
Idling checks2)
Idling speed rpm 770...8701)
CO content Vol.% 0.2...1.21)
Digifant control unit3)
Part No. when renewing=> Parts microfiche
Governed speed rpm 6400...6500
1) Up-to-date specifications:
3) Match Digifant control unit to engine after replacement. To do this carry out idling check => Page 33
Notes:
◆ The work sequence is dependent upon the programme level of the Digifant control unit. Programme level
number => Page 2 , connecting fault reader V.A.G 1551 and selecting engine electronics control unit.
◆ Idling speed and CO content are not adjustable.
◆ The basic setting of the engine is carried out with the fault reader V.A.G 1551.
◆ In the basic setting, the Digifant control unit is matched to the throttle valve potentiometer at idling speed.
The ignition timing control is switched off.
=> Repair group 20, removing and installing parts of the fuel supply system, adjusting accelerator cable
- -> Connect ignition tester V.A.G 1367 with pick-up clamp V.A.G 1367/8 or ignition tester V.A.G 1767.
- -> Connect CO tester V.A.G 1363A with adapter V.A.G 1363/3 to CO sampling pipe.
- -> Pull off crankcase breather hose at pressure regulating valve and seal hose opening to intake hose -
arrow-.
- Interrogate and erase fault memory, eliminate faults if necessary => Page 3 .
- Press ⇒ button.
- Input 04 for "Initiate basic setting" and confirm with Q.
Note:
Input the display group number corresponding to the programme level number of the control unit.
1) Up-to-date specifications:
- Press ⇒ button.
- Input 06 for "End output" and confirm with Q.
Do not continue with check until 00000000 appears in the 4th display zone.
Note:
◆ If one or more 1s appear in display zone 4, test conditions are not satisfied:
=>Meaning of figures in display zone 4,
Page 36 .
1) Up-to-date specifications:
1) Up-to-date specifications:
- Press ⇒ button.
- Input 06 for "End output" and confirm with Q.
The control unit is only in check or adjust mode if 00000000 appears in the 4th display zone (conditions satis‐
fied). the conditions are not satisfied if one or more 1s appear in display zone 4:
◆ 01000000 = Signal from automatic gearbox control unit to Digifant control unit not OK.
◆ 00100000 = Air conditioner not switched off
◆ 00000100 = Throttle valve not closed
◆ 00000010 = Engine speed outside permitted range
◆ 00000001 = Coolant temperature below 85 °C
Note:
The work sequence is dependent upon the programme level of the Digifant control unit. Programme level
number => Page 2 , connecting fault reader V.A.G 1551 and selecting engine electronics control unit.
- Connect fault reader V.A.G 1551 and select engine electronics control unit (address word 01); selection is
carried out with engine idling.
=> Page 2
- Input 08 for "Read measured value block" function and confirm with Q.
- Increase engine speed to approx. 2500 rpm for 1 minute, then allow engine to idle.
- Read Lambda voltage in display zone 3. Lambda voltage must fluctuate by
more than 0.3 V.
- Press ⇒ key.
- Input 06 for "End output" and confirm with Q.
If Lambda voltage does not fluctuate by more than 0.3 V (after checking with increased engine speed):
Do not continue with check until 00000000 appears in 4th display zone.
Note:
◆ If one or more 1s appear in display zone 4, test conditions are not satisfied:
=>Meaning of numbers in display zone 4,
- Increase engine speed to approx. 2500 rpm for 1 minute, then allow engine to idle.
- Read Lambda voltage in display zone 3. Lambda voltage must fluctuate by
more than 0.3 V.
- Press ⇒ key.
If Lambda voltage does not fluctuate by more than 0.3 V (after checking with increased engine speed):
Notes:
◆ The work sequence is dependent upon the programme level of the Digifant control unit. Programme level
number => Page 2 , connecting fault reader V.A.G 1551 and selecting engine electronics control unit.
◆ The following check checks the overrun cut-off. If this check is OK., then the acceleration and full load
enrichment are also OK.
- Connect fault reader V.A.G 1551 and select engine electronics control unit (address word 01); selection is
carried out with engine idling.
=> Page 2
- Input 08 for "Read measured value block" function and confirm with Q.
Note:
If something different is indicated on the display:
=> Fault reader operating instructions
If the displayed figure does not increase and does not drop back to 0 ms:
Notes:
◆ The work sequence is dependent upon the programme level of the Digifant control unit. Programme level
number => Page 2 , connecting fault reader V.A.G 1551 and selecting engine electronics control unit.
◆ Recognition of the following operating conditions are checked with this check: idling, part load, full load and
overrun cut-off.
- Connect fault reader V.A.G 1551 and select engine electronics control unit (address word 01); selection is
carried out with engine idling.
=> Page 2
Note:
Checking overrun operation recognition by briefly increasing engine speed to over 3000 rpm (coolant temper‐
ature above 60 °C):
- Interrogate and erase fault memory. Eliminate faults if necessary => Page 3 .
- Check throttle valve potentiometer
=> Page 40 .
Note:
The work sequence is dependent upon the programme level of the Digifant control unit. Programme level
number => Page 2 , connecting fault reader V.A.G 1551 and selecting engine electronics control unit.
- Connect fault reader V.A.G 1551 and select engine electronics control unit (address word 01); selection is
carried out with engine idling.
=> Page 2
- Input 08 for "Read measured value block" function and confirm with Q.
Note:
- Slowly open throttle valve and watch angle display in display zone 3.
The figure must increase uniformly over
the complete range.
- Press ⇒ key.
- Input 06 for "End output" and confirm with Q.
Note:
- Slowly open throttle valve and watch angle display in display zone 3.
The figure must increase uniformly over
the complete range.
- Press ⇒ key.
1.12 - Matching automatic gearbox control unit and throttle valve potentiometer to one
another
Note:
The automatic gearbox control unit and throttle valve potentiometer must be matched to one another after the
following work has been completed:
Matching
=> Automatic gearbox 096; Repair Group 01; Self-diagnosis; Introduction of basic setting Self-diagnosis Intro‐
duction of basic setting
Note:
The work sequence is dependent upon the programme level of the Digifant control unit. Programme level
number => Page 2 , connecting fault reader V.A.G 1551 and selecting engine electronics control unit.
• Engine cold
- Connect fault reader V.A.G 1551 and select engine electronics control unit (address word 01); selection is
carried out with engine idling.
=> Page 2
- Input 08 for "Read measured value block" function and confirm with Q.
- Observe coolant temperature figure in display zone 1. 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.
◆ Open circuit is indicated by - 40 °C.
◆ 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.
- In put 06 for "End output" and confirm with Q.
- Observe coolant temperature figure in display zone 2. 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.
◆ Open circuit is indicated by - 40 °C.
◆ 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.
- In put 06 for "End output" and confirm with Q.
Note:
The work sequence is dependent upon the programme level of the Digifant control unit. Programme level
number => Page 2 , connecting fault reader V.A.G 1551 and selecting engine electronics control unit.
- Input 08 for "Read measured value block" function and confirm with Q.
Note:
- -> Lift air filter upper part, spray intake air temperature sender (G42) with commercial refrigerant spray and
observe temperature reading. Temperature must
drop.
- Press ⇒ key.
- In put 06 for "End output" and confirm with Q.
Note:
- -> Lift air filter upper part, spray intake air temperature sender (G42) with commercial refrigerant spray and
observe temperature reading. Temperature must
drop.
- Press ⇒ key.
- In put 06 for "End output" and confirm with Q.
Note:
The work sequence is dependent upon the programme level of the Digifant control unit. Programme level
number => Page 2 , connecting fault reader V.A.G 1551 and selecting engine electronics control unit.
- Connect fault reader V.A.G 1551 and select engine electronics control unit (address word 01); selection is
carried out with engine idling.
=> Page 2
Note:
If no fault is found:
- Renew air mass meter => Page 19 , item 7 and perform idling check.
Note:
If no fault is found:
- Renew air mass meter => Page 19 , item 7 and perform idling check.
Note:
The work sequence is dependent upon the programme level of the Digifant control unit. Programme level
number => Page 2 , connecting fault reader V.A.G 1551 and selecting engine electronics control unit.
- Connect fault reader V.A.G 1551 and select engine electronics control unit (address word 01); selection is
carried out with engine idling.
=> Page 2
- Input 08 for "Read measured value block" function and confirm with Q.
Note:
If something different is indicated on the display:
=> Fault reader operating instructions
Note:
The fuel pressure regulator controls the fuel pressure dependent upon intake manifold pressure.
=> Rep. Gr. 20; Removing and installing parts of fuel system; checking fuel pump
Note:
To prevent fuel spray when loosening connections wrap a cloth around the connection.
Attention!
The pressure gauge cut-off tap must be closed (lever at 90 to throughflow direction -arrow-).
- -> Pull fuel pipe -1- off connection -2- on cold start valve.
- Connect pressure gauge V.A.G 1318 with adapter 1318/10 to fuel pipe -1-.
08.93 ▸
- -> Remove plug -1- on fuel manifold and connect pressure gauge V.A.G 1318 with adapter V.A.G 1318/1
to fuel manifold.
- Start engine and run at idling speed.
- Check fuel pressure.
Specification: Approx. 2.5 bar
- -> Pull vacuum hose off fuel pressure regulator at junction piece -arrow-. The fuel pressure must rise to
approx. 3.0 bar.
- Switch off ignition
- Check for leaks and holding pressure by watching pressure drop on gauge. After 10 minutes there must be
a residual pressure of
at least 2 bar.
=> Rep. Gr. 20; Removing and installing parts of fuel system; checking fuel pump
Note:
Before removing the pressure gauge, release fuel pressure by opening the cut-off tap. When doing this hold a
container over the connection.
▸07.93
Note:
The cold start valve injects only at coolant temperatures below 15 °C.
- -> Pull injector connector -1- off fuel manifold -2-.
- -> Pull off plug of cold start valve (N17) and connect diode test lamp V.A.G 1527 with aux. cables from V.A.G
1594.
Otherwise:
Removing
Note:
The ratchet and socket SW5, with 1/4' drive, are particularly suitable for removing the socket head screws.
- Pull fuel manifold with injectors out left, facing direction of travel.
- -> Remove screw -1- and lever upper part of fuel manifold -2- of fuel manifold -3- at point indicated by arrows.
- -> Clamp threaded end of socket head screw (M6) in a vice and press out injectors.
Installing
Note:
- -> Insert injectors into fuel manifold upper part and moisten O-rings -arrows- with oil.
- Press fuel manifold upper part with injectors into the fuel manifold.
Checking resistance
- -> Check resistance on connection -2- for all injectors using hand multimeter V.A.G 1526 and aux. cables
from V.A.G 1594.
Specification: 3.7...5.0 ω(all 4 injectors OK.)
- Remove fuel manifold with injectors => Page 52 , removing and installing injectors.
- -> Remove bolt -1- and lever fuel manifold upper part -2- of fuel manifold - 3 - as indicated by arrows.
- Repeat check on individual injectors, if necessary renew injector(s).
Specification: 15...20 ω
- Connect supply and return pipes to fuel manifold, using extension hoses if necessary.
- ▸07.93: Reconnect cold start valve hose.
- -> Place injectors in the measuring appliance V.A.G 1602.
- Attach connector -2- to fuel manifold connection -1-.
- -> Pull 2-pin plug off coolant temperature sender (G62).
- Pull plug off ignition transformer.
- Operate starter. The injectors must spray uniformly.
- Switch off ignition and check injectors for leaks. No more than
2 drops/min
may leak from each injector.
Note:
Notes:
◆ The vacuum in the intake system will cause the leak detector spray to be drawn in with the outside air. The
leak detector spray reduces the ignitability of the mixture. This leads to a drop in engine speed and to a
significant increase of the CO content.
◆ The safety precautions listed on the container must be adhered to.
- -> Connect ignition tester V.A.G 1367 with pick-up clamp V.A.G 1367/8 or ignition tester V.A.G 1767.
- -> Connect CO tester V.A.G 1363A with adapter V.A.G 1363/3 to CO sampling pipe.
- Start engine and run at idling speed.
- Systematically spray parts of the intake system with engine leak detector spray.
- Check for leaks in the area of intake system sprayed and eliminate leak.
Note:
The limiting screw is set in the factory and must not be altered. However, if the screw is turned inadvertently
set again as follows.
- -> Turn limiting screw -arrow- out until a gap exists between stop lever -1- and limiting screw -arrow-.
- Turn limiting screw in, until it just touches the lever -1-.
Note:
To determine the exact point of contact, place a thin piece of paper between lever -1- and limiting screw. By
continually moving the paper to and fro, and at the same time turning the limiting screw in, the exact point of
contact can be determined.
Manual gearbox
1 Intake manifold
2 For air conditioning system
3 To brake servo
◆ Not on vehicles with ABS
4 For air conditioning system
◆ On vehicles with ABS
5 Fuel pressure regulator
6 Temperature regulator
◆ Connect vacuum unit hose to hose connection which is made of metal or with groove.
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7 Vacuum unit
8 Activated charcoal filter solenoid valve 1 (N80)
9 From activated charcoal filter
10 Junction piece
11 Throttle valve housing
Automatic gearbox
1 Intake manifold
2 For air conditioning system
3 To brake servo
◆ Not on vehicles with ABS
4 For air conditioning system
◆ On vehicles with ABS
5 Vacuum booster
◆ Not on vehicles with ABS
6 To intake hose
7 Fuel pressure regulator
8 Temperature regulator
◆ Connect vacuum unit hose to hose connection made of metal or with groove
9 Vacuum unit
10 Activated charcoal filter solenoid valve 1 (N80)
11 From activated charcoal filter
12 Junction piece
13 Throttle valve housing
28 - Ignition system
Notes:
◆ 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.
◆ Electrical check of Digifant injection and ignition system => Page 9
◆ The injection and ignition system control unit is equipped with self diagnosis.
◆ Components marked with a * are checked via the self diagnosis.
◆ Before carrying out repairs and for fault finding, interrogate the fault memory.
=> Page 3 , interrogating and erasing fault memory
62 28 - Ignition system
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
1 HT cable
◆ Check for continuity
2 Suppressor
◆ 0.6...1.4 kω
3 Terminal 1
4 Terminal 15
5 Ignition transformer output stage (N157)
◆ Checking => Page 70
6 10 Nm
7 Ignition transformer (N152)
◆ Checking => Page 69
8 Connector
9 Earth strap
10 Knock sensor 1 (G61)*
◆ On engine block
Volkswagen Technical Site: http://vwts.ru http://vwts.info
11 20 Nm
◆ Tightening torque influences the function of the knock sensor
12 Spark plug connector
◆ 4...6 kω
13 Spark plug, 30 Nm
◆ Type and electrode gap
=> Page 66
14 20 Nm
15 Clamp
16 O ring
◆ Renew if damaged
17 Distributor with Hall sender (G40)
◆ Installing => Page 66
◆ Checking and adjusting ignition timing => Page 33 , idling check
◆ Checking Hall sender
=> Page 68
64 28 - Ignition system
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
18 Dust cap
19 Rotor arm
◆ Marking: R1
◆ 0.6...1.4 kω
20 Distributor cap
◆ Check for cracks and signs of tracking
◆ Check contact wear
◆ Clean before fitting
◆ Check carbon brush for wear and freedom of movement
21 Screening cap
Engine code 2E
Ignition timing1)
Checking and adjusting => Page 33 ,
Idling check
Ignition timing 1-3-4-2
Spark plugs1)
VW/Audi 101 000 026 AB
101 000 038 AA
Manufacturer's designation N7 BMC
14G-8 DTU
Electrode gap 0.7...0.9 mm
Tightening torque 25 Nm
1) Up-to-date specifications:
- -> Set flywheel -A- or drive plate -B- to TDC No. 1 cylinder.
Engine removed
66 28 - Ignition system
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
- -> Set vibration damper (V-belt pulley) to TDC No. 1 cylinder.
- -> Mark on camshaft sprocket must align with arrow on cylinder head.
- -> Align oil pump shaft drive tongue with threaded hole.
- -> Insert distributor so that the rotor arm points to No. 1 cylinder mark on the distributor body.
- Before fitting, clean distributor cap and check for cracks and signs of tracking, renew if necessary.
- Checking and adjusting ignition timing =>Page 33 , checking idling speed.
- -> Connect ignition tester V.A.G 1367 with pick-up clamp V.A.G 1367/8 or ignition tester V.A.G 1767.
- Start engine and run at idling speed.
- Set ignition tester to 2800 rpm.
- Slowly increase speed to slightly above 2800 rpm until the ignition timing (advance angle) is indicated.
Specification: 35...45 ° before TDC
- Carry out electrical check => Page 9 , if necessary renew control unit (J169).
- -> Bridge test box -2- sockets 1 + 35 with short cable -4- (V.A.G 1598/18-1).
- Bridge test box -2- sockets 4 + 45 with cable -1- (V.A.G 1594/22).
Note:
If the measuring cable -1- (V.A.G 1594/22) is equipped with one plug and two sockets, connect plug to socket
4 of test box and one socket to cable V.A.G 1594/19 and long measuring cable V.A.G 1598/18-1 to socket 45
of test box.
- Connect diode test lamp V.A.G 1527 with connector -3- (V.A.G 1594/15) and long cable -4- (V.A.G
1598/18-1) to sockets 44 + 45.
- Operate starter.
LED must flicker
68 28 - Ignition system
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
If no voltage is present:
- -> Check primary resistance with hand multimeter V.A.G 1526 between terminals 1 and 15.
Specification: 0.5...0.7 ω
- Check secondary resistance with hand multimeter between terminals 4 and 15.
Specification: 3...4 kω
- Remove ignition transformer and unscrew the ignition transformer output stage (N157) => Page 63 .
- Repeat check.
Checking activation
- Pull off connector for injectors and cold start valve (if fitted).
- -> 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 and 3 of the plug.
- Operate starter and check ignition signal from Digifant control unit.
LED must flicker
70 28 - Ignition system
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
LED flickers:
Warning!
During the following test do not touch the terminals of the ignition transformer or test cables.
- Switch on ignition.
LED must light up for
1...2 seconds
- Operate starter.
The LED must flicker,
if necessary renew output stage.