4-cylinder injection engine (4 valves), mechanical Page 1 of 1

Technical characteristics
Engine number

→The engine number ("reference letters

motor" and "order number") is found at-
on top of the engine casing ventilation,
the front of the cylinder block.

A sticker bearing the "reference letters"

motor" and the "order number" is furthermore
attached to the toothed belt protection.

The reference letters for the engine are also

mentioned on the identification plate
of the vehicle.

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Technical specifications
Engine characteristics

Reference Letters ABF

Fabrication 08.92
Cylindrical l 2.0
Power kW to 1/min 110/6000
Couple Nm at 1/min 180/4800
Bore ø mm 82.5
Course mm 92.8
Compression 10.5
RON mini 95 unleaded
Injection DIGIFANT
Ignition DIGIFANT
Knock regulation x
Self-diagnosis x
Lambda regulation x
Catalyst x
Overfeeding -

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Engine: removal and installation

Engine: removal and installation

Special tools, controllers and auxiliaries

necessary

◆Baquet V.A.G 1306

Clamp for spring-blade belts V.A.G 1921
Lever 3299
◆2024 A Suspension Device
◆V.A.G 1202 A workshop crane
◆Support 3180
◆Grease G 000 100
V.A.G 1331 torque wrench (5 to 50 Nm)
V.A.G 1332 torque wrench (40 to 200 Nm)
Cable clamp

If the engine needs to be disassembled:

◆VW 540 engine support

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Engine: removal and installation

Indications for removal

First, check if a coded car radio is installed. If so, ask for the anti-theft code number.
The engine is removed with the gearbox by
the front.
With the ignition off, disconnect the ground strap from the battery.

Note:

All the detached or cut cable ties during the removal

the engine parts must be put back in the same place during

the rest.

Drain the coolant => page 19-10.

Place the lock holder with bolted parts:

Bodywork - Assembly work; repair group 50;

Before bodywork; Locking mechanism with bolted parts: removal and reinstallation

Vehicles with air conditioning:

Take into account the comments and additional assembly work => page10-10.

Unscrew the gear shift control from the transmission:

02A mechanical gearbox with 5 speeds; repair group 34; Gear control: restoration

Remove the clutch receiver cylinder

hydraulic

Mechanical gearbox 02A with 5 speeds; repair group 30; Clutch control: refurbishment

Unscrew the power steering reservoir and place it aside.

Unscrew the power steering vane pump with
its support and set it aside; the hoses remain
tuned in.

→Hang as follows the device of

2024 A suspension with the support
3180 and lift it slightly with the
workshop crane

On the pulley side:

4th bore of the bush in position 1

On the flywheel side:

1st hole of the splice in position 7

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Attention
Use safety pins on the
crochets and adjustment pins.

Note:

◆The adjustment positions of the caliper-

supports numbered from 1 to 4 must
be oriented towards the pulley.
The boreholes made in the
splits must be counted from
the hook.

Remove the engine support and take it out

the mechanical assembly at the front with it
lifting.

Note:

The mechanical assembly must be guided with

precaution

when it is removed to avoid any

damage on

the bodywork.

For the execution of assembly work, the

the engine must be fixed with the engine mount
VW 540 on the mounting stand.

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Engine: removal and reinstallation

Instructions for reinstallation

The rest must be carried out in the reverse order, taking into account the following:

Check the wear of the clutch release bearing and replace it if necessary.
Lightly grease G 000 100 the clutch release bearing, the guiding sleeve of the bearing.
disengaging and the tooth of the primary shaft.

Check if the adjusting sleeves

destined for engine/transmission centering
found in the cylinder block; the case
if necessary, set them up.
During the lowering of the whole
mechanics, ensure to manage a
sufficient distance in relation to the trees
from the bridge.
During the reinstallation of the fixation of the

engine, ensure that the rib on

the right rear console as well as
the hollowing out on the front console
snap into the tenons of the
metal-rubber skates -arrows-.
Adjust the engine mounting without
constraint by printing some
shocks.
Reinstall the lock holder with parts
bolted

Bodywork - Assembly work; group

of repair 50;

Before bodywork; Locking door with

bolted parts: removal and reinstallation

Rest the receiver cylinder of

the clutch
hydraulic

Mechanical box 02A with 5 speeds; group

repair 30; Clutch command:
restoration

Reinstall the vane pump from

assisted direction:

Vehicles with air conditioning:

Rest the air conditioner compressor:

Heating, air conditioning; Group reply 87

Topping up the fluid of

cooling => page19-10

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Adjust the throttle cable => page

20-11
Make a basic adjustment:

Digifant injection and ignition system

(4 valves); Group of repeater 24; System
injection and ignition Digifant; Adjustment of
base: process

Electrical connections and layout

cables:

Current flow diagrams,

Electrical equipment troubleshooting and
Mounting locations

Check the headlight adjustment,

correct if necessary:

The Specialist and the Interview

If necessary, settle the order

speeds via cables:

02A 5-speed mechanical gearbox; Group

repair 34; Gear control:
remise en état; Commande des vitesses:
adjustment

Vehicles 10.94

Adapt the control device of

the engine electronics for the anti-theft system:

Digifant injection and ignition system

(4 valves); Repair group 24;
Digifant injection and ignition system;
Control device for electronics
engine: adaptation to the immobilizer
electronics

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Engine: removal and installation

Clamping couples
Face Torque couple
Engine on BV M10 60 Nm
M12 80 Nm
Engine support/gearbox on gearbox and cylinder block 45 Nm
Bridge trees on flanged trees 45 Nm
Exhaust pipe on manifold 40 Nm
Thermal insulation protection right bridge tree on cylinder block 35 Nm
Engine support on bodywork 50 Nm

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Engine: removal and installation

Fixation of the mechanical assembly

Clamping couples

(lubricated bolts)

AV fixation of the mechanical assembly

A = 50 Nm
B = 55 Nm
C = 50 Nm

AR fixing of the mechanical assembly

A = 25 Nm
B = 50 Nm
C = 25 Nm

AR G fixation of the mechanical assembly

A = 50 Nm
C = 25 Nm
D = 25 Nm

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Engine: removal and installation

Engine mount silent blocks: replacement

Special tools, controllers and auxiliaries

necessary

Support device 10-222A with legs 10-222A/1 and bracket 3180

3302 Tapping Mandrel
Support part VW 432

Workflow

Set up the maintenance device 10-222A with feet 10-222A/1.

Set up the support 3180 in

the hooking eye on the cylinder head
as well as the maintenance device and
slightly pre-tension the engine.
Remove the engine support.
Remove the washers from the sockets
separation by leveraging with a
tongs (then replace the washers)
damaged, e.g. twisted).
Extract the spacing bushings and
detach them
silent blocks.
Set up the new ones
silent blocks and drive in the sockets
spacing as far apart as possible.

→Set up the washers -1- on

the silent blocks -2- through the
mandrel for broaching 3302.
Set up the pressure socket
the chuck of
mating 3302 and fitting by the press
the slices
on the spacing sleeves and the
master. Use VW 432
as support.
If necessary, eliminate the
exceeding or the edge that has
trained on the mating.

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Engine: removal and reinstallation

Remarks and additional assembly work on vehicles.
air conditioner
Attention
The refrigerant circuit of the air conditioner must not be opened.

Note:

The refrigerant circuit should only be opened in workshops with qualified personnel, as well as
tools and workshop equipment needed.

To be able to install and remove the engine without needing to open the cooling circuit:

Unscrew the liquid reservoir of the air conditioner and let it hang in the void.
Remove the trapezoidal ribbed belt => page 13-11.
Lower and drop the lock holder with parts
bolted

Bodywork - Assembly work; repair group 50;

Before bodywork; Locking mechanism with bolted parts: removal and reinstallation

Unscrew the refrigerant pipe support on the

longeron.

→Remove the compressor from

air conditioner and place it aside with the
lock holder so that the
refrigerant hoses -arrows- are
relieved.

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Engine: disassembly and assembly

Engine: disassembly and assembly

Note:

Yes, during work on

repair on the engine,
a large quantity of
metal shavings or
of abrasion residues -
coming from a seizing,
e.g. damage
cushions of
crankshaft and connecting rod -
is observed in
the engine oil, it is necessary,
to avoid damage
subsequent, clean
carefully the
oil conduits thus
that the oil radiator.

I =>page 13-2

II => page 13-5

III => page 13-7

Part One

1. 20 Nm
2. 10 Nm
3. Protection sup.
of belt
cramped
4. M8: 25 Nm
M10: 40 Nm
5. Tensioner pulley
◆ 02.94
semi-
automatic
Control the

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tensioning pulley
semi-
automatic
of belt
cranted
=> page13-
17
6. Timing belt
Before the
deposit,
identify the
sense of
rotation
Control
usury
◆ Do not fold
◆Deposit and
rest
tender
=> page13-
13
7. Protection AR of
toothed belt

8. Tree pinion
intermediate
9. Belt pulley
crankshaft
10. 65 Nm
11. 90 Nm + 1/4 of
tour
additional
(90°)
◆To pour
loosen and
tighten, use
the against-
support 3099
◆ Replace
◆Put in
lubricated place
The tightening

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additional
can be carried out
in several
passes.
Protection inf. of
timing belt
V-belt
trapezoidal
◆Locate the
sense of
front rotation
the removal
◆Deposit and
to rest
=> page13-11
14. Pulley
◆ For pump of
liquid of
cooling
◆Version for
belt to
veins
trapezoidal

15. Shock absorber of

vibrations
◆ Montage
possible
in a
position
only
drillings
offset
◆Ensure the
position during
of the rest
from the
belt
cramped
=> page13-
13
Belt

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trapezoidal
Adjust the
tension of the
belt
trapezoidal

Chassis-suspension;
Group of rep. 48; View
of the entire assembly:
vane pump, reservoir
of supply, pipelines
hydraulic; Belt
trapezoidal: tension

17. Pulley
For pump of
liquid of
cooling
◆Version for
belt
trapezoidal
18. Pulley
19. Tensioner pulley
20. Clamping lever
Hood
dust cover

Part II

20 Nm
2. Upper part of
intake manifold
3. Joint
◆ Replace
4. Valve cover
5. Cover seals
cylinder head
◆Replace in case
of damage
Before the implementation of

place, to endure of
D 454 300 A3 the
hat junctions
of the bearing/head
and the hollowing out in

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half form
moon
6. Cylinder Head

◆Submit and
to rest
=> page15-6
◆ After the
replacement
renew everything
the liquid of
cooling

Head gasket
Replace
◆After the
replacement
renew everything
the liquid of
cooling
8.45 Nm
Hanging eyelet
10. Shaft gear to
came
◆Ensure that the
position during
the rest of the
timing belt
page13-13
Head bolt
◆ Take into account

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instructions from
assembly and of
the order of
loosening and
tightening
=> page15-6
◆ Take into account the
version
=> page15-5, fig.
2
12. 10 Nm
Bistro
Replace the seal
in case
of damage

Part III

1. Cylinder block
◆Submit and
rest the
flasks
sealing
and the steering wheel-
engine
=> page13-
18
◆Submit and
rest it
crankshaft
page13-24
Disassemble
and assemble
the piston and the

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connecting rod
=> page13-28
2. 20 Nm + 1/4 turn
additional
(90°)
◆ Replace
3. Detector of
clicks
4. 20 Nm
The couple of
tightening to a
influence on the
operation
the detector
of clicks
5. Joint
◆ Replace
6. Cork
◆ With
catch-up of
game

7. Spacing piece
8.25 Nm
O-ring
Replace
10. Joint
◆Replace in case
of damage
11. Ventilation of the casing
engine
Oil filter support
Oil radiator
Product coating
AMV 188 100 02
the surfaces
getting in touch
with the flange, at
the outside of the
seal ring

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Manage a
sufficient guard
with the
components
environments
◆ Take into account the
note
=> page13-1
14.25 Nm

15. Oil Filter

Loosen with
handle of
tightening
Hand tighten
Take into account
instructions
of figurant pose
on the filter to
oil
16. 10 Nm
17. Transmitter of
engine regime
Support rings
19. Support
20. 45 Nm
21. 10 Nm
22. Clamping element

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23. 30 Nm
24. O-ring
◆Replace in case
damage
25. Support

26. Clamp lever

27. Face to face
rectangular
28. Liquid pump of
cooling
◆ Dismantle
and assemble
=> page19-8
Oil cart
30. 20 Nm
Loosen or
tighten the screws
steering side
engine with the
extension socket
3249
31. Support
◆ For pump to

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little wings
32. Joint
Replace
Before the implementation of

place, endure
of 'D2' the
loose joints
sealing/block
cylinders

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Engine: disassembly and assembly

Trapezoidal ribbed belt: removal and reinstallation

Note:

Identify the direction of rotation before removing the trapezoidal belt. Ensure proper
positioning of the belt in the pulleys during its installation.

Special tools, controllers and auxiliaries

necessary

Lever 3299

Trapezoidal belt: removal

Identify the direction of rotation of the ribbed belt.

→Soulever le galet-tendeur avec le

lever 3299 and remove it
trapezoidal ribbed belt of
side of the pulley of
the alternator.
Remove the trapezoidal belt from the
power steering vane pump:

Remove the ribbed belt

trapezoidal.

Trapezoidal ribbed belt: resting

Note:

Ensure the correct positioning of the belt at

trapezoidal grooves in the pulleys during
to rest.

Place the ribbed belt

trapezoidal on the shock absorber of
vibrations.
Reinstall the trapezoidal belt of the
steering assist vane pump

Lift the tensioner pulley with 3299 and

install the ribbed belt
trapezoidal.

→Belt-driven order without compressor

air conditioner

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Belt drive order with compressor

of air conditioner

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Engine: disassembly and assembly

Timing belt: removal and installation, tension
(Calibration of the distribution)

Special tools, controllers and auxiliaries

necessary

Lever 3299
Key for Matra V159 nuts
V.A.G torque wrench 1331 (5 to 50 Nm)

Motors without semi-automatic tensioner roller:

◆Trapezoidal belt and toothed belt control device VW 210

Deposit

Remove the trapezoidal ribbed belt => page 13-11.

Remove the trapezoidal belt tensioner pulley.
Remove the vibration damper and the upper and lower belt guard.
Identify the direction of rotation of the toothed belt.
Loosen the tensioner roller and remove the toothed belt.

Rest

Conditions

● The engine must be at most at a temperature of

the hand.
The pistons must not be at top dead center.

Note:

During the rotation of the camshaft, the valves may collide with the pistons that are at the TDC.

Work progress

Place the toothed belt on the toothed belt/crankshaft sprocket and the intermediate shaft sprocket.
(ensure the rotation direction) and replace the lower cover of the toothed belt.
Reinstall the crankshaft vibration dampener (ensure the mounting position, offset bores).

Place the camshaft gear on

the PMH reference of cylinder 1. The
camshaft pinion reference must
coincide with the arrow placed on the
cylinder head cover -A-.

Valve cover installed:

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The mark located on the shaft purlin at

The cam must match with the cylinder head -B-.

→Bring the crankshaft to TDC of

cylinder 1. The reference of PMH of the steering wheel-
engine and the mark of the crankcase
The clutch must coincide -D-.

Engine removed:

The mark located on the shock absorber of

vibrations and the marker placed on the protection
the timing belts must coincide -C-.

Place the timing belt on the sprocket

of the camshaft.

Engines with semi-automatic tensioner-less pulley:

→ Tension the toothed belt; at this

turn the tensioner pulley with the key
for nuts (e.g. Matra V159) in the
direction of the arrow.
Value on graduated scale for VW
210: 13 to 14
Tighten the locking nut on the roller.
tensioner.
Torque: 45 Nm

Engines with semi-automatic tensioner roller:

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→Tighten the toothed belt in

turning the tensioner pulley with a wrench
for nuts (e.g. Matra V159) in the
Arrow sense to the limit.
Loosen the tensioner pulley until
that the markers are located exactly
one above the other -arrow-.
Tighten the locking nut on the roller.
tensioner.
Tightening torque: 25 Nm

Turn the crankshaft twice in the

sense of
engine rotation, replace it at TDC
and check
the adjustment.
Replace the upper protection of
synchronous belt.
Reinstall the belt tensioner pulley at
trapezoidal ribs.
Torque: 20 Nm
Reinstall the ribbed belt
trapezoidal => page13-11.

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Engine: disassembly and assembly

Semi-automatic toothed belt tensioner: control

Control condition

Timing belt in place and tightened

Conduct of the control

Turn the crankshaft twice in the direction of rotation.

to the engine until it is back at TDC
of the cylinder 1.

→Note the position of the cleat of the roller.

tension -arrow-. Press hard on
the toothed belt with the thumb. The
Taquet must move.
Loosen the toothed belt.
Turn the crankshaft twice in the
direction of rotation
of the engine.
Then check the position of the cleat.
He must have returned to his position
initial.

If the stop does not return to its position

initial

Replace the tensioner pulley.

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Seal flanges and flywheel: removal and installation

Seals and flywheel: removal and installation

Note:

Restorations on
the clutch

Mechanical box 02A

5-speed; group of
repair 30;
Clutch: re-engagement
state

O-ring
For the
deposit,
submit it
flaccid
sealing
◆ Rest
with10-203
Lubricate
slightly
the lip
sealing
of the
O-ring
Seal ring
◆ Replace
=> page
13-21
3. 25 Nm
Flaccid
sealing
5. Joint
◆Remplacer

Cylinder block
Place and replace
the crankshaft
page13-24
◆ Disassemble and
assemble the piston
and the connecting rod

page13-28
7. 60 Nm + 1/4 turn (90°)
additional
◆Replace
Flywheel
Block with 3067
for the removal and the

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rest
Intermediate plaque
Must rest on the
adjustment sleeves
◆ Do not
damage/distort
during the work of
montage
10. 10 Nm
11. Sealing gasket with
seal ring
Do not replace
completely
◆Set up the
sealant flask
spare with the
socket included in
the delivery set

12. Intermediate tree

◆ Axial play: 0.25
mm maxi
13. O-ring
◆ Replace if there is
damage
14. Sealing gasket
of the intermediate tree
15. 25 Nm

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Sealing flanges and flywheel: removal and installation

Crankshaft seal ring - pulley side -: replacement

Special tools, controllers, and auxiliaries

necessary

Counter support 3099

Ring gasket extractor 2085
Attachment device 3083
◆Torque wrench V.A.G 1331 (5 to 50 Nm)
◆V.A.G 1332 torque wrench (40 to 200 Nm)

Deposit

Remove the trapezoidal ribbed belt => page 13-11.

Remove the toothed belt => page 13-13.

Remove the belt sprocket

crankshaft/connecting rod. To this end, block
the toothed belt sprocket with the
counter-support 3099.
To guide the ring extractor
joint, screw in the cylindrical head screw of
3083 all the way to the stop in the
crankshaft.
Loosen the internal part of
the 2085 ring-joint extractor of
two turns (approx. 3 mm) of the part
outer and block it with the screw
mottled.

→Lubricate the threaded head of the extractor

of the sealing ring, to put it in place and, in
applying strong pressure, screw it in
as far as possible in the ring-
joint.
Loosen the knurled screw and turn it
inner part against the crankshaft
until the seal ring is
extract.

Repose

Lightly lubricate the lip

sealing of the sealing ring.

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Set up the guide bushing

from 3083 on the dowel.
Push the gasket ring over the
guiding sleeve.

→Fit the gasket ring to the

press until fully engaged with the socket
of pressure 3083.
Replace the toothed belt => page
13-13.

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Vilebrequin: removal and installation

Vilebrequin: removal and reinstallation

Half bearings 1,
2, 4 and 5
For hats
from level 1, 2 and
5 without throat
degreasing
For hat
from level 4 and
cylinder block
with throat of
greasing
◆ Do not
invert them
semi-
bearings
Rodes (the
to identify
2. 65 Nm + 1/4 turn
supplementary (90
°)
◆ Replace
◆To measure the
radial game
tighten to 65 Nm
without however
continue to
to tighten
3. Landing hats
Hat of
level 1: from
side of the
pulley
◆ Hat of
level 3 with
hollows
for rings
support
The spurs of
fixation of
half-
bearings
block
cylinders/hat
of bearing
must be
superimposed

Half-bushing
3
Pour
hat
of bearing
without throat

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degreasing
For block-
cylinders
with throat
of
greasing
5. Support washer
◆ For
hat of
level 3
To hold
account of
the fixing
6. Target
Pour
transmitter
of regime
◆ Replace
7. 10 Nm + 1/4 of
tour
supplementary
(90°)
Replace
8. Crankshaft
Axial game at
nine: 0.07 to
0.17 mm
Limit
of wear and tear:
0.25 mm
◆ Measure the
radial game
with a thread
of
plastigage
At nine: 0.02
at 0.06 mm
Limit
of wear:
0.17 mm
◆ During the
measurement of
radial game,
do not
turn the
crankshaft

◆ Cotes of
crankshaft
=> page
13-27

9. Rondelle

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support
◆For block-
cylinders
level 3

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Vilebrequin: removal and reinstallation

Vilebrequin: sides
(Dimensions in mm)

Coast
from øtourillons ømanetons
rectification
-0.022 -0.022
54.00 47.80
Origin side
-0.042 -0.042
-0.022 -0.022
53.75 47.55
Coast I
-0.042 -0.042
-0.022 -0.022
53.50 47.30
Cote II
-0.042 -0.042
-0.022 -0.022
53.25 47.05
Côte III
-0.042 -0.042

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Piston and connecting rod:

Piston and connecting rod:

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Piston and connecting rod: disassembly and assembly

Piston and connecting rod: disassembly and assembly

Piston rings
◆ Cut at 120 °
◆Remove and replace with a piston ring pliers
The 'TOP' marker must be on the side of the piston head.
◆Control the game at the cut => fig.1
◆Control the game in height => fig.2
2. Piston
◆Control => fig.3
Identify the mounting position and alignment to the cylinder
The arrow placed on the piston head must be oriented towards the pulley.
Rest using a grip handle for piston rings

3. Bielle
◆ Do not replace
that by games
completes
◆ Identify
the pairing
in the cylinder -
B-
◆Position of
montage
The benchmarks -
A- must
to be oriented
pulley side
◆ With bore
oil for
greasing of
the axis of
piston
4. Connecting rod cap
◆Respect the
position of
montage
5. 30 Nm + 1/4 of
tour
additional
(90°)
◆ Lubricate it
threading and the
surface
support
To measure
the radial game,
tighten to 30
Nm without
however
continue to
to tighten

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6. Flap of
suppression, 27
Nm
Pressure
of opening:
2.5 to 3.2
bar

Oil injector
◆ For the
cooling
the piston
8. Half bearing
◆Respect the
position of
montage
Do not
invert them
half
bearings
Rhodian
Ensure that
that they be
good
positioned
in the spurs
of maintenance
Axial game
At nine: 0.05 to
0,31 mm
Usury limit:
0.37 mm
◆ Measuring the play
radial with a
son of
plastigage
At nine: 0.01 to
0.06 mm
Usury limit:
0.12 mm
Do not turn
the crankshaft
during the
play measurement
radial
With bore
oil for
greasing of
the piston axis

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9. Cylinder block
◆Control
the bore of
cylinders
fig.4
◆ Pistons and
cylinders
braces
=>page13-
34

10. Connecting rod bolt

Stop segment
12. Piston shaft
◆ In case of
sliding
difficult,
heat the
piston at 60°
C
◆Deposit and
resting with
the VW tool
222a

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→Fig. 1 Game for cutting the segments of

piston: control

Push down from the top the segment to

right angle in the lower opening
from the cylinder, at a distance of about 15
mm from the edge of the cylinder.

Segment of
Cup game
piston
limit
to nine
of wear
Segment.
mm 0.20...0.40 1.0
compress.
Segment
mm 0.25...0.50 1.0
scraper

→Fig. 2 High game of the segments of

piston: control

Before the inspection, clean the throat of

segment.

Segment of
High game
piston
limit
new
usury
Segm.
mm 0.02...0.07 0.15
compress.
Segment
mm 0.02...0.06 0.15
scraper

→Fig. 3 Piston: control

Special tools, controllers, and auxiliaries

necessary

Standard micrometer 75 to 100 mm

Measure about 10 mm from the bottom edge

and following a shifted diameter of 90 °
in relation to the piston axis. Difference
in relation to the nominal value
0.04 mm max

Cote nominale => page13-34; Pistons

and cylinders: dimensions

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→Fig. 4 Cylinder bore: control

Special tools, controllers, and auxiliaries

necessary

Precision Bore Comparator 50

at 100 mm

Measure in 3 points diagonally in

the transverse -A- and longitudinal -
B-. Differences compared to the rating
nominal
0.08 mm max

Cote nominale => page13-34; Pistons

and cylinders: dimensions

Note:

The measurement of the cylinder bore must not

to be carried out when the cylinder block is fixed
at the assembly base with the engine mount
VW 540, due to the risk of errors in
measure.

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Piston and connecting rod: disassembly and assembly

Pistons and cylinders: dimensions
Reaming allowance øpiston bore of the cylinder
Country of origin mm 82,485 82,51
Cote I mm 82,735 82.76
Cote II mm 82,985 83.01

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Cylinder head: removal and installation

Cylinder head: removal and reinstallation

Control the compression rate => page 15-9

Note:

When reinstalling a replacement-standard cylinder head with the camshaft installed, the contact surfaces
Between the cup pushers and the sliding path of the cams must be lubricated after reinstallation.
of the cylinder head.

◆The plastic washers delivered to protect the open valves must not be removed.
that immediately before the installation of the cylinder head.
◆If you replace the cylinder head, you must also completely renew the coolant.

Cork
Replace the seal
in case
of damage
2. 20 Nm
3. Upper part of
intake manifold
4. Joint
◆Replace
5. Cylinder head cover
6. 10 Nm
7. Cover seals
cylinder head
◆Replace in case
of damage
◆ Before the implementation of

place, to endure
D 454 300 A3 the
hat junctions
of bearing/cylinder head
and the hollowing out in
half-
moon
8. 20 Nm

Support
10. Cylinder head

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◆Contrôler le
bending
=> fig.1
Rest
page 15-6
◆ After the
replacement
renew
all the
liquid of
cooling
11. Cylinder head gasket
Replace
After the
replacement
renew
all the
liquid of
cooling
12. Cylinder head bolt
Order to
to respect
during
loosening
and you
tightening
=> page15-
6
Cylinder head:
rest
◆ Take into account
from the version
=> page15-
5, fig.2
13. Tree pinion to
came
Take into account
of her
position during
of the assembly
of the
belt
craned
=> page13-
13

Carnation
of hang-up
15. M8: 25 Nm
M10: 40 Nm
Belt
cranked
◆ Control
usury
Do not
plier

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◆Deposit and
to rest
tender
=> page13-
13
17. Tensioner pulley
◆ 02.94
semi-
automatic
Control the
pebble
tensioner
semi-
automatic
of belt
cranked
=> page13-
17
18. Sup. Protection
of strap
cramped

→Fig. 1 Cylinder head: control of

warping

Maximum allowable warpage: 0.05 mm

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→Fig. 2 Characteristics of
differentiation of cylinder head bolts

A - Smooth head bolt

◆for the old head gasket

B - Knurled head bolt -arrow-

for the metal cylinder head gasket

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Cylinder head: removal and installation

Cylinder head: remove and reinstall

Special tools, controllers, and auxiliaries

necessary

◆Baquet V.A.G 1306

Clamp for spring blade collars V.A.G 1921
Guide pivot 3070
◆V.A.G 1331 torque wrench (5 to 50 Nm)
◆V.A.G 1332 torque wrench (40 to 200 Nm)

Prerequisites

The engine must be at most at the temperature of

the hand.
The pistons should not be at TDC.

Deposit

First, check if a coded car radio is installed. If so, ask for the anti-theft code number.
With the ignition off, disconnect the ground strap from the battery.
Remove the trapezoidal ribbed belt => page 13-11.
Loosen the toothed belt tensioner pulley => page 13-13.
Drain the coolant now => page19-10.
Remove the valve cover.

→Loosen the cylinder head bolts

in the indicated order and unscrew them
completely.
Retirer la culasse avec précaution.

Rest

Note:

Do not remove the new head gasket from

his packaging just before
to ask him/her.
Handle the new seal with a
extreme caution. The
damages lead to
sealing defects.
◆If the metal head gasket is installed
in replacement of an old joint in
soft material, it is also necessary to lay
new cylinder head bolts.
Differentiation characteristic => fig.
2

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Stuff the cylinders with rags

clean to prevent impurities and
the abrasion residues do not manage
between the cylinder wall and the piston.
Also avoid impurities and
the abrasion remains do not reach
in the coolant.
Clean carefully now
the sealing surfaces of the cylinder head
and the engine block by preventing the
formation of stripes or scratches
longitudinal (if the sandpaper is
used, its grain must not be
less than 100).
Carefully remove the remnants
of abrasion and sanding and remove the
chiffons.
Bring the piston of cylinder 1 to the point
high death and turn the crankshaft
slightly in the opposite direction.

→For centering, screw in the pivot of

guidance
from 3070 in the bolt holes
of
cylinder heads 8 and 10.

Install the head gasket.

The registration (part number of
rechange) must be readable.
Install the cylinder head, install in
place the remaining 8 cylinder head bolts
and shake their hands.
Unscrew the guiding pivot with the
pivot turn of
3070 through the boreholes of
bolts and put in
place the head bolts.
Tighten the cylinder head bolts in
the indicated order, proceeding as
suit
Pre-tighten all bolts to 40 Nm.
Then tighten all the bolts to 60.
Nm.
Then turn all the bolts of a
1/4 extra turn
(90°) with the help of a rigid key.
Finally tighten all the bolts again
once a quarter turn
supplementary (90°).

The rest of the assembly is carried out in a way that

similar in the reverse order of the deposit.

For the reinstallation of the timing belt and the

timing of the distribution
=> page13-13

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For filling the liquid of

cooling => page19-10.

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Cylinder head: removal and reinstallation

Compression rate: control

Special tools, controllers and auxiliaries

necessary

Spark plug wrench 3122B

Compression gauge recorder V.A.G 1381 or V.A.G 1763
V.A.G 1331 torque wrench (5 to 50 Nm)

Control condition

The engine oil temperature must

be at 30°C min

Conduct of the control

Unplug the plug connection

regime transmitter -1-.
Push the accelerator to the floor.
floored by a second mechanic.
Check the compression rate at
the help of the pressure meter-recorder
V.A.G 1381 or V.A.G 1763.

Note:

The handling of the compressimeter is described

in the respective user manual.

Keep the starter engaged until

that the measuring device no longer indicates
of pressure increase.

Compression ratio values:

At nine: 10 to 13 bar
Usury limit: 7.5 bar

Permissible difference between all cylinders:

3 bar

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Valve order: restoration

Valve order: refurbishment
Note:

The cylinder heads presenting

cracks between the
valve seats or
between a ring of
valve seat and the
threading of a candle
can be reused
without loss of their
longevity when it comes to
of slight cracks,
larger than 0.5 mm max,
or when only the
first fillets of
spark plug threads are
fissured.

65 Nm
2. 15 Nm
3. Hat of
step
◆Position of
montage
=>fig.2
Order of
montage
=> page
15-23
Tree to
cames:
deposit and
repose
Enduiring
slightly
of product
of
sealing
AMV 174
004 01 the
surface
support
of the
hats
of bearing
on the
pine cone
from tree to
shoes and
on
the lamp lighter

4. Chain of
command

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Before the
deposit
identify the
sense of
rotation
(position of
montage
=> page
15-23
5. Camshafts
◆Control the
axial game
=>fig.1
◆Deposit and
to rest
=> page
15-23
◆ Control the
radial game
with a thread
from
plastigage
Limit
of wear and tear
0.1 mm
Faux-round:
0.01 mm
maxi
◆ Spotting
and shimming
from the
distribution
=> page
15-16, fig.
3
6. Pushbuttons in
bowl
Do not them
to invert
◆ With
catch-up
hydraulic
of the game of
valves
◆Contrôler
=> page
15-21
Deposit
with the
surface
support
oriented
downwards
◆ Before the
rest
control the

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axial game of
the tree to
cames
=>fig.1
◆ Lubricate it
surface
support

7. Clamps
Upper bowl of
valve spring
9. Springs of
valve
Submit and
to rest
Cylinder head
deposited:
with 2037
posée: =>
page15-29
Seals
de tiges de
valves
replacement
10. Sealing of
valve stem
◆Replace=>
page15-29
11. Inner bowl of
valve spring
12. Valve guide
Control
page15-27
Replace =>
page15-27
The version
provided for the
repair
includes a
collect
O-ring
◆ Lubricate
slightly there
lip
sealing
from the ring
joint
◆Replace=>
page15-20

14. Cylinder head

Rectify the
headquarters of
valve
=> page
15-17

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15. Coast of
rectification
Measure the
slope
minimal to
through a
bore of
bolt
Coast
minimal:
118,1 mm
Valves
Do not
rectifier
only the
breaking in is
admissible
◆ Cotes of
valves
=> fig.4

→Fig.1 Camshaft: clearance control

axial

Special tools, controllers, and auxiliaries

necessary

Universal support for VW comparator

387
Comparator

Perform the measurement with the pushbuttons in

saucers placed, the first and the last
bearing caps being installed.

Wear limit: 0.15 mm max

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→Fig. 2 Tree trunk hats

supports: mounting position

The cutouts of the landing hats

must be oriented towards the admission side of
the bolt -arrow-.

→Fig.3 Identification of cam shafts,

calibration of the

distribution

Identification between the pairs of cams of

cylinders 1 and 2

-arrows-

Exhaust tree -A-: 051 102

Intake manifold -B-: 051 101 or 051

101A

Timing of the distribution for lift

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1 mm valve

1 ° you.
Peace be upon
R.F.A.: 38 °
A.O.E.: 39 °
R.F.E.: 1°

→Fig. 4 Valves: dimensions

Note:

The valves must not be ground.

Only their break-in is permissible.

Cote Admission Escape

øa mm 32.0 27.0
ø mm 6.97 6.94
c mm 95.5 98.0
α <° 45 45

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Valve order: restoration

Valve seats: grinding

Special tools, controllers and auxiliaries

necessary

Depth gauge
Valve seat grinding machine

Note:

To restore engines with leaky valves, it is not enough to simply grind the valves.
valve seats and the valves or to replace them. In particular on engines having a
important mileage, it is necessary to check the wear of the valve guides
=> page15-27.
Only rectify the valve seats to achieve a perfect seat. Before proceeding to the
correction, it is necessary to calculate the maximum allowable correction dimension. If the correction dimension is
outdated, the operation of the hydraulic compensation for the valve clearance is no longer ensured and the
the cylinder head must be replaced.

You calculate the maximum allowable correction margin as follows:

Engage the valve and press it hard against its

seat.

Note:

If the valve is replaced during the repair, use the new valve for the measurement.

Measure the gap between the end of the

valve stem and the upper edge
from the cylinder head.

Calculate the maximum correction rating

admissible based on the measured gap and
from the mini rate.

Mini stakes:
Intake valve 34.4 mm
Exhaust valve 34.7 mm

Measured deviation minus minimum rating

maximum allowable correction rate.

Example:

Measured deviation 35.1 mm

- Mini rate 34,4 mm
Adjustment wedge
= 0.7 mm
maximum allowable

*) On the figures illustrating the rectification

valve seats, the dimension of

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the maximum admissible rectification is represented

like side 'b'.

→Intake valve seat:

rectification

Ø31.2 mm
maximum adjustment rate
a
admissible
b
1.5 to 1.8 mm
c
If necessary, adjust the ring
valve seat with a
Z strawberry at 75°
45 °
lower edge of the cylinder head
30 °
range angle
upper rectification angle

→Exhaust valve seat:

rectification

= ø26.6 mm
a
maximum adjustment rate
b
admissible
c
= env. 1.8 mm
Z
lower edge of the cylinder head
45 °
range angle
30 °
upper correction angle

*) For the calculation of the adjustment rating

max admissible
=> page15-17.

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Valve order: repair

Camshaft seal ring: replacement

Special tools, controllers, and auxiliaries

necessary

Support counter 3036

Ring-joint extractor 2085
◆Fitting device 10-203
◆V.A.G 1331 torque wrench (5 to 50 Nm)
◆V.A.G 1332 torque wrench (40 to 200 Nm)

Deposit

Remove the upper belt guard.

Loosen the camshaft sprocket

(use the counter-support
3036).
Bring the camshaft pinion
on the PMH reference of cylinder 1 in
having a rotation done to
crankshaft. The mark on the pinion
the camshaft must coincide with the
arrow on the cover-culasse -A-.

When the valve cover is removed:

The mark located on the shaft pinion at

the cam must coincide with the head -B-.

Loosen the tensioner pulley and remove it

timing belt
Remove the camshaft gear.
Tighten the pinion fixation screw
from the camshaft to the stop in
the camshaft with a washer
spacer.
Unscrew the inner part of
the ring joint extractor 2085 of
two turns (about 3 mm) of the piece
outside and block it using a
wavy face.
Lubricate the threaded head of the extractor
seal ring, put it in place and, in
applying strong pressure, the screw it in
as deeply as possible into
the sealing ring.
Loosen the knurled screw and turn it
internal part against the camshaft
until the extraction of the sealing ring.

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Rest

Lightly lubricate the lip

sealing of the gasket ring.
Install the sealing ring with a
sleeve and mount it to the press
up to the stop with tool 10-203 and
a screw 10-203/1.
Reposition the camshaft gear and
tighten it to
65 Nm
(use the counter-support 3036).

The continuation of the assembly is carried out in a way that

similar in the reverse order of the drop.

For the reinstallation of the toothed belt and the

timing of the distribution
=> page13-13

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Valve order: overhaul

Hydraulic pushers in cup: control

Special tools, controllers and auxiliaries

necessary

V.A.G torque wrench 1331 (5 to 50 Nm)

Thickness gauge
Wood or plastic wedge

Note:

◆Only replace the push buttons in the cup that are complete (they cannot be adjusted or refurbished).
The irregular noises produced by the valves during engine start-up are normal.

Conduct of the control

Start the engine and run it until the radiator fan has turned on once.
circuit.
Run the engine for two minutes at around 2500 RPM.

If the hydraulic cup pushers are still noisy, check the pusher or the pushers.
defective by proceeding as follows:

Remove the upper part of the intake manifold and the valve cover.
Turn the crankshaft clockwise until the camshafts of the cup pushers are
the controls are located at the top.
Now calculate the play between the cams and the
pushers.

→Push the cup button down

slightly down using a
wooden or plastic scale.
If it is possible to slide a
thickness gauge of 0.2 mm between
the camshaft and the pushrod
cup, replace the pusher.

Note:

After the installation of cup buttons

new, do not start the engine during
about 30 minutes. The elements
Compensating hydraulics must be set up.
in place (the valves would otherwise hit the
pistons.

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Valve order: refurbishment

Camshafts: removal and installation

Outils spéciaux, contrôleurs et auxiliaires

necessary

Support bracket 3036

V.A.G torque wrench 1331 (5 to 50 Nm)
V.A.G torque wrench 1332 (40 to 200 Nm)
◆Sealing product AMV 174 004 01

Deposit

Remove the upper timing belt cover, the upper part of the intake manifold and the
cylinder head cover.
Loosen the camshaft sprocket (use the counter-support)
3036).

Bring the camshaft gear

up to the PMH reference of cylinder 1
by causing a rotation to
crankshaft. The mark is located on the
camshaft sprocket must align
with the cylinder head.
Loosen the tensioner pulley and remove it
timing belt.
Remove the camshaft sprocket.
Remove the ignition coil.
Identify the command chain of
the intake camshaft before the
place (e.g. to put an arrow in)
the direction of rotation with paint.

Note:

Do not spot the chain with a blow

point, a notch or a mark
similar.

Intake camshaft

→Start by depositing the

landing hats 5 and 7, as well as the
last hat.
Alternately loosen diagonally
the hats of level 6 and 8.

Exhaust camshaft

Start by putting down the hats

of level 1 and 3, as well as the first and

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the last hat.

Loosening alternately diagonally
the hats of level 2 and 4.

Rest

Condition to be fulfilled

● The pistons must not be at

PMH.

Lubricate the bearing surfaces of

camshafts.

Set up the camshafts

with the chain in such a way that the
markers found on the gables of
coincident chain -arrows-.

Note:

◆Ensure the identification of the direction of rotation.

During the replacement of the hats

landing, ensure that the cutouts
hats should be oriented to the side
admission of the cylinder head -fig. 15-650-.

Intake camshaft

Alternately tighten the hats of

level 6 and 8
diagonally and
block them at
15 Nm.
Rest the other landing hats
and block them at
15 Nm
also.

Exhaust camshaft

Alternately tighten the hats of

level 2 and 4
diagonally and
block them at
15 Nm.
Lightly coat with product
sealing AMV 174 004 01 the surface
support of the landing hats on the
camshaft sprocket and on

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the lamp lighter.

Rest the other level hats
and block them at
15 Nm
also.
Reposition the camshaft gear and
to tighten it to
65 Nm
(use the counter support 3036).

The rest of the assembly is carried out in a manner

similar in the reverse order of the deposit.

For the replacement of the toothed belt and the

timing of the distribution
=> page13-13

Note:

After the installation of cup push buttons

new, do not start the engine during
about 30 minutes. The elements
compensating hydraulics must be set up
in place (the valves would otherwise hit the
pistons)

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Valve order: refurbishment

Valve guides: inspection

Special tools, controllers, and auxiliaries

necessary

Universal support for VW 387 comparator

Comparator

Conduct of the control

→Install a new valve in the

guide. The end of its stem must
coincide with the guide. Given the
difference in diameter of the rods, place
only an intake valve
in an admission guide and a
exhaust valve in a guide
exhaust.
Determine the toggling game.
Usury limit:
Intake valve guide = 1.0
mm
Exhaust valve guide =
1.3 mm

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Valve service: restoration

Valve guides: replacement

Special tools, controllers and auxiliaries

necessary

Ejector 3121
Socket 30-23
◆Fitting base 3123
◆Hand drill 3120 and cutting fluid

Deposit

First, check if it is still possible to rectify the valve seat rings and, if necessary,
sealing surface of the cylinder head. Otherwise, the valve guides can no longer be replaced.

Using tool 3121, extract to the

press the worn valve guides at
to leave the side of the room of
combustion. Use socket 30-23
as support.

Rest

→Oil the new guides and,

the help of tool 3121, to fit them on
the press up to the collar in the
cold cylinder head, from the side of the tree
to cams. To this end, use the support
3123.

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Note:

Once the guide is inserted up to the

collect, the pressure

the fitting must not exceed 10 kN

(env. 1.0 t), otherwise

the collar may break.

Sharpen the valve guide with

the hand reamer 3120. To do this,
must use liquid
coupe.
Seat cutting of valves
page15-17.

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Valve ordering: refurbishment

Valve stem seals: replacement
(when the cylinder head is installed)

Special tools, controllers and auxiliaries

necessary

V.A.G 1331 torque wrench (5 to 50 Nm)

Torque wrench V.A.G 1332 (40 to 200 Nm)
Spark plug wrench 3122B
◆Extraction device 3047A
Mounting device 2036
◆Flexible pressure VW 653/3
◆Mounting lever VW 541/1A with pressure piece VW 541/5
◆Pusher 3129

Deposit

Start by installing the camshaft

=> page15-23.
Remove the cup pushers and place them with the support surface facing down.
Be careful not to swap the push buttons.
Unscrew the spark plugs with the wrench
with candles 3122B.
Bring the cylinder piston to the 'bottom dead center' position.
Now screw the VW 653/3 pressure hose into the spark plug hole.
Apply a
minimum pressure of 6 bar
the pressure flexible and remove the valve springs.
Set up the assembly device 2036 and adjust the bearings to the height of the threaded bolt.
Remove the valve springs using the VW 541/1A mounting lever and the pressure piece.
VW 541/5.

Note:

Remove the stuck valve cotters

by applying a few light taps with a mallet
on the mounting lever.

→Admission side

Note:

To prevent the mounting lever from slipping

on the mounting device, it is necessary
if necessary, to make a notch on a
distance a = 50 mm on the lever.

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→Exhaust side

Extract the seals from the rods of

valves with 3047A.

Rest

→In order to prevent any damage

on the new seals of the rods
of valves, place the socket in
plastic -A- on the valve stem.
Lubricate the stem sealing of
valve -B-, place it on the tool
of assembly 3129 and do it
slide carefully on the guide of
valve.

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Components of the lubrication system: removal and reinstallation

Parts of the lubrication system: removal and reinstallation

Note:

If, in the case of engine repair, we find the presence of metallic chips and residues
abrasion in large quantities in the engine oil - due to seizing, e.g. damage to
crankshaft and connecting rod bearings - carefully clean the oil passages and replace
beyond the oil radiator to avoid subsequent damage.
◆The oil level must not exceed the maximum mark - risk of damaging the catalyst.
References => page 17-8, fig. 3.

Check the oil pressure => page 17-8

Oil capacities1):

without oil filter 3.8 l

with oil filter 4.3 L

Updated values:

Anti-Pollution Service Binder

Specification of the engine oil:

Use engine oils that comply with the VW 500 00 or 501 01 standard. Only in exceptional cases: oils
multigrades conforming to API-SF or SG.

Cork
2. Joint
◆Replace if there is
damage
3. Guide tube
Remove for
suck the oil
Oil gauge
The oil level
must not
to exceed the
maximum marker.
◆ References => fig.3
Bouchon
With catch-up
of the game
6.25 Nm
7. Spacing piece
8. Joint
Replace

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Transmitter of
temperature
(G8), 10 Nm
◆ For
indicator
of
temperature.
of oil
◆Blanc
10. Switch of
oil pressure
0.3 bar (F22), 25
Nm
◆ Brun
◆Cable:
blue/black
◆ Control

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=> page17-8
In case of
default
sealing,
remove it
O-ring
and the
replace
11. Switch of
oil pressure
1.8 bar (F1), 25
Nm
White
Cable: yellow
Control
page17-8
◆ In case of
fault
sealing,
set aside
O-ring
and there
replace
12. Filter support at
oil
13. Check valve,
5 Nm

14. O-ring
◆ Replace
15. Radiator
of oil
◆ Coat
d'AMV 188
100 02 the
surfaces
of contact
with the
flaccid, in
outside of
the ring
joint
◆ Housekeeper
a guard
sufficient
with the

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components
environments
To hold
account of
note
=> page17-
1
Oil filter
Loosen
with
handle of
tightening
Tighten at the
main
To hold
account of
directives of
montage
featured on
the filter to
oil
17. Gables
◆Control the
game of exchanges
dents
=> fig.1
Control the
axial game
fig.2

18. Lid of
oil pump
with flap of
suppression
◆ Pressure
of opening:
5.7 to 6.7
bar
19. 10 Nm
20. 20 Nm
21. 20 Nm
◆Submit and
rest
with the
socket
extension
3249
22. Support

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23. 45 Nm
24. Drain valve
of oil, 40 Nm
25. O-ring
◆ Replace
Oil pan
◆ Before the
montage
clean the
surface
sealing

27. Joint
◆ Replace
◆ Before the implementation of
place, endure
from 'D2' the
surfaces of
flange joint
seal/block
cylinders
28. Suction line
Clean the sieve
in case
of clogging
29. Anti-partition
projections
◆ Don't mount it
that when the
oil pump

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is deposited
30. Valve of
suppression, 27 Nm
Pressure
of opening:
2.5 to 3.2 bar
Oil nozzle
◆ For the
cooling
the piston
32. Pignon
training
Pour
training
of the pump to
oil

→Fig. 1 Oil pump: play control

between the teeth of the pine nuts

At nine: 0.05 mm

Wear limit: 0.20 mm

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→Fig. 2 Oil pump: clearance control

axial

Wear limit: 0.15 mm

→Fig. 3 Markings on the oil gauge

1 - Maximum reference
2 - Mini marker
a - Zone above the zone
hatch to the maximum marker: do not
top up the engine oil.
b - Oil level found in
the hatched area: we can do
the engine oil top-up.
c - Zone extending from the minimum marker
up to the hatched area: make the adjustment
motor oil without exceeding a
filling quantity of 0.5 l.

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Parts of the lubrication system: removal and reinstallation

Oil pressure and oil pressure switch: control

Note :

Control of the operation and restoration of the optical and acoustic oil pressure indicator:

Current flow diagrams, Electrical equipment troubleshooting and Mounting locations

Special tools, controllers, and auxiliaries

necessary

V.A.G 1342 oil pressure controller

V.A.G 1527 LED indicator lamp
◆V.A.G 1594 Metrology Adapter Set

→Remove the pressure switch

of oil 1.8 bar (white insulation) and the
fishing in the control device.
Screw the control device into the
oil filter support -2-, instead
of the oil pressure switch.
Connect the brown cable -1- of the device to
control at
the mass (-).
Connect the diode indicator light
V.A.G 1527 with auxiliary cables
from the V.A.G 1594 to the positive pole (+) of the
battery and pressure switch
of oil (F22) -B-. The diode
Electroluminescent must light up.
Start the engine and increase
slowly the diet.
At a pressure of
0.15 to 0.45 bar,
the light-emitting diode must
to go out; otherwise
replace the pressure switch
oil 0.3 bar.
Connect the LED indicator to the
oil pressure switch 1.8 bar
(F1) -A-.
At a pressure of
1.6 to 2.0 bar
the light-emitting diode must
to turn on; otherwise,
replace the pressure switch
of oil.
Continue to increase the speed.
At 2000/min and a temperature of 80 °
C, the oil pressure must be 2.0
mini bar.

At a higher regime, the oil pressure does not

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must not exceed 7.0 bar. If necessary,

replace the oil pump cover with
the pressure relief valve.

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Cooling system parts: removal and reinstallation

Cooling system components: removal and installation

Note:

◆When the engine is hot, the cooling system is under pressure. Before making repairs, remove the
pressure if necessary.
◆The hoses are secured at the junction points by spring clips. In case of repair,
only use spring clip collars.
◆It is recommended to use the V.A.G 1921 pliers for installing spring-clamp collars.

Coolant: draining and filling => page 19-10

Coolant mixing proportions => page 19-10, Coolant: drain and

filling

Carry out the leak test of the cooling system with V.A.G 1274 and 1274/3.

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Cooling system parts: removal and replacement

Cooling system parts on the body side

1. Radiator
◆ Submit and
to rest
=>page19-
13
Renew
the liquid of
cooling
in full
after the
replacement
Belt
trapezoidal
Only
in case
equipment
additional
Guiding ring
◆Respect the
position of
montage
◆ Fixation by
clips to
lock holder
-6-
4. Fan of
radiator
◆Deposit and
to rest
=>page19-
13
5. Fan
additional
◆ Only
in case
equipment
supplementary
◆Submit and
rest
=>page19-
13

6. Lock holder
7. Durite
superior
◆ Verse
the nozzle
of connection
=>page
19-5
position -3-
Lower hose

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Vers
pump of
liquid of
cooling.
=>page
19-6,
position
16-
9.4 Nm
10. Sheet of
connection
11. Cache
12. Vase
of expansion
13. Towards the pipe of
liquid of
cooling.
◆ =>page
19-6
position
13-
14. Cork
◆Control
with the
devices
V.A.G
1274 and
1274/4
◆ Pressure
of
control
1.4 to 1.6
bar

15. Thermocontactor
(F18), 35 Nm
For fan
electric
Temperatures of
commutation
1st gear
engagement:
92 à 97°C
stop: 84 to 91 °
C
2nd speed
triggering
99 à 105°C
stop: 91 to 98 °
C

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Cooling system parts: removal and installation

Cooling system parts on the engine side

Liquid pump of
cooling
◆ Disassemble
and assemble
=> page19-8
2. 20 Nm + 1/4 turn
supplementary
(90°)
Replace
3. Towards the part
higher of
radiator
◆=>page19-3
position -7-
Retention clip
O-ring
◆ Replace
Thermocontactor
(F165)
For 3rd gear
the fan
electric
Only in
case
equipment
additional
◆ Temperatures
of
commutation
March: 110 to
115°C
Stop: 105 at
110°C

7. 10 Nm
8. Nozzle of
connector
Transmitter of
temperature of
liquid of
cooling. (G62)
10 Nm
Transmitter
of the indicator of
temperature of
liquid of
cooling
G2, 10 Nm
11. Verse

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the exchanger of
heat
12. Coming from
the exchanger of
heat
Coming from the vase
of expansion
◆ =>page
19-3
position
13-
Liquid pipe
of
cooling
15. Radiator
of oil
◆ Deposit and
to rest
=>page
17-4
16. Coming from the
lower part of the
radiator
◆=>page
19-3
position -8-

17. Support
18. 30 Nm
19. Belt
trapezoidal/to
veins
trapezoidal
◆Submit and
put it back
belt to
veins
trapezoidal
=> page13-
11
◆ Settle the
tension of the
belt
trapezoidal

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Chassis-suspension;
Group of reply. 48; View
of the overall assembly:
vane pump,
supply tank
hydraulic conduits;
Trapezoidal belt:
tension

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Cooling system parts: removal and installation

Coolant pump: disassembly and assembly

20 Nm
2. Pulley
◆Version for
belt to
veins
trapezoidal
Liquid pump of
cooling
◆ Control the
good
operation
4. Joint
Replace
5. Regulator of
coolant
◆Control:
heat the
regulator at
water bath
Start
of opening:
approx. 85°C
◆ End: approx. 105 °
C
Course
of opening:
7 mm mini
Connection nozzle

O-ring
Replace
Retention clip
9.10 Nm
10. Flask
11. Pulley
◆ Version for
belt to
veins
trapezoidal

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Cooling system components: removal and installation

Coolant: draining and filling

Special tools, controllers, and auxiliaries

necessary

Baquet V.A.G 1306

Spring Blade Clamp for V.A.G 1921 Hose Clips
Densimeter

Drainage

Open the cap of the coolant expansion tank.

→Extract the retaining clip -3-,

remove the connector nozzle -2- from the
liquid regulator flask
cooling -4- and unplug it
either unscrew the flange of the
coolant regulator
-4-.

If the cooling system was full

coolant additive G 11 -
green color - so far:

Before reattaching the hose or the flange

and to make adjustments with the new one
coolant G 12 -
red color-, rinse as follows
cooling system:
Eliminate as well as possible the
remnants of coolant from
cooling system. To this end,
blowing in, for example, compressed air into
the expansion tank.
Seal the cooling system
and fill it with water
pure.
Faire tourner le moteur pendant env. 2
minutes.
Drain the fluid again
cooling and to infuse again
compressed air times in the system
cooling.

Note:

Take into account the guidelines applicable to

the elimination.

Filling

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Note:

Standard coolant additive:

June 1996 G11 -green color-

07.96 G 12 -red color-

Attention
Never mix one with the other.
coolant additives -G
11- and -G 12-. The mixture causes
serious damage to the engine.

The G 12 (G 11) and liquid additives

of cooling bearing the mention
in accordance with TL VW 774 D (C)
prevent damage caused by frost and
corrosion, as well as scaling; in
besides, they increase the temperature
boiling. For these reasons, the
cooling system must
must be filled out completely
the year of antifreeze product and
anticorrosive.

◆Particularly in countries with a climate

tropical, the liquid of
cooling contributes, thanks to its
boiling point plus
high, to the operational safety
of the engine in case of
strong solicitations.
Frost protection must be ensured
down to -25°C
environment (in countries with a polar climate
down to -35°C
environment).
◆In the hot season or in the countries
hot, the concentration
coolant must not
so not either
be diminished by adding water.
proportion of additive
coolant antifreeze
must be 40%
minimum.
Yes, for climatic reasons, a
antifreeze protection
more important is necessary, the
proportion of G 12
may be increased, but up to 60
% maximum
antifreeze protection down to -40°C
environment), otherwise the said
protection would decrease and power

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cooling
would degrade.
If the radiator, the heat exchanger,
the cylinder head or the head gasket have been
replaced, do not reuse the liquid
used coolant.
◆In case of a new filling of
cooling system, use
only the G 12.
Antifreeze and anticorrosive product G 11
should only be used for restoration
the level if the system of
cooling is still filled with G
11.
Characteristic: green color

Recommended mixing proportions:

Protection
Proportion G
antifreeze Water
antifreeze 121)
until
2.2 l
-25°C 40% 3.3 l
2.75
-35°C 50% 2.75 l
l

The quantity of liquid of

Cooling may vary depending on the equipment
of the vehicle.

→Slowly restore the level of the

coolant up to
maximum mark on the expansion tank. The
filling takes about 5 minutes.
Close the jar lid
of expansion.
Run the engine until
fan activation.
Check the fluid level of
cooling and do
the tip if necessary. When the
the engine is at its temperature
of operation, the liquid of
cooling must be located
at the maximum mark; with a cold engine, it must
to be understood between the minimum and maximum markers
maxi.

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Cooling system parts: removal and installation

Radiator and fan: removal and reinstallation

Special tools, controllers, and auxiliaries

necessary

Baquet V.A.G 1306

Spring Blade Clamp for V.A.G 1921

Deposit

Drain the coolant => page 19-10

Remove the front bumper:

Bodywork - Assembly work; Repair group 63;

Front bumper; Front bumper: removal and reinstallation

Disconnect the radiator hoses.

Unplug the connection plug of the thermal switch and the radiator fan.
Lower the headlights:

Electrical equipment, Repair group 94; Headlights: restoration

Unscrew the screws fastening the radiator and remove the radiator from the front.

Véhicules équipés d'un climatiseur:

Take into account additional remarks and assembly work => page19-15.

Rest

The rest is done in the reverse order; it is then necessary to take into account the following:

Check the coolant level => page 19-10

Check the headlight adjustment, correct it if necessary:

The Specialist and the Interview

Remarks and additional assembly work for vehicles equipped with an air conditioning system

Attention
The refrigerant circuit of the air conditioner must not be opened.

Note:

To avoid damaging the condenser and the refrigerant lines/hoses, care must be taken not to
extend, bend, or twist the pipes and hoses.

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Remove the air filter.

Unscrew the air conditioner liquid tank and let it hang in the air.
Unscrew the radiator mounting screws.
Unscrew the support collar(s) of the pipes.
refrigerant.
Unscrew the radiator condenser and pull it as far as possible.
that possible forward.
Remove the radiator between the condenser and the
lock holder.

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Fuel system components: removal and installation

Power supply system parts: removal and installation

Note:

The flexible joints are secured by screw clamps, spring clip clamps, or clamps.
tightening.
◆Systematically replace the hose clamps with spring-band clamps or screw clamps.
◆The fuel hoses on the engine must not be
braked only by spring blade collars.
It is not permitted to use tie wraps or
screw collars.
It is recommended to use the V.A.G 1921 pliers for fitting spring band clamps.

Take into account the security measures => page 20-9.

Take into account the cleanliness rules => page20-10

Adjust the throttle cable => page 20-11

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Fuel system components: removal and installation

Fuel tank with added parts and fuel filter: removal and
rest

Note:

After all the work on

the discharge unit of
fuel and the indicator of
fuel level, please
make sure that the pipes
curved or flexible between
the discharge unit and the
flaccid do not touch the
fuel tank, which
could transmit the
pump noises.

Cork
2. Clamping ring
3. Rubber cuvette
4. O-ring
◆Replace if there is
damage

5. Clapet à gravité
For the
deposit
unclick it
valve by
the high outside
of the nozzle
of
filling
◆ Control the
passage
in the
valve

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Valve
vertical:
open
Valve
tipped over from
45°
closed
6. Driving
ventilation
Towards the
tank to
charcoal
active
=>page20-
23, position
-8-
◆ Towards the
cuvette
rubber
position -3-,
on the
vehicles
without
system of
reservoir at
coal
active
7. Liaison to the
mass
8. Air vent
Control
=>page20-
8, fig.2
For the
deposit,
to drive in
slightly
the
locking
vers
the inside
arrow and
extract the
valve

9. Flexible return
◆ Blue or
blue marker
Coming from
distributor of
fuel

Injection system and

Digifant ignition (4
valves); Group of rep.

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24; Injection system and

Digifant ignition; Part
restoration

10. Coupling nut, 75

Nm
◆Deposit and
resting with
3217
11. Flexible guide
12. Flaccid
◆ Respect the
position of
montage on the
reservoir to
fuel
=> page20-8,
fig.1
13. Flexible/tube
wavy
of food
◆ Must not
touch the
reservoir to
fuel
when the
flaccid is
mounted, which
could risk
transmettre les
sounds of the
pump
14. O-ring
◆ Moisturizer of
fuel
before the
montage
◆Replace if
and to
damage

15. Flexible/pipe
wavy back
◆ Must not
to touch
tank to
fuel
when the
flaccid is
this mounted
who
might risk
of
transmit
the noises
of the
pump
16. Unit of

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refoulement of
fuel
◆Deposit and
to rest
=> page
20-11
◆ Pump to
fuel
control
=> page
20-13
Transmitter
of the indicator of
level of
fuel
◆ Adjust the
version
adjustable

Schemes of
current path,
Electrical troubleshooting and
Locations of
montage

18. Sieve
19. Strap of
tightening
To hold
account of
the
difference
of
length

20. Support
◆ For
straps of
tightening
21. 25 Nm
22. Reservoir to
fuel
During the
deposit,
support
with
the elevator
for
engine and
BV V.A.G
1383 A
23. Driving
of nutrition

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Noir
Towards the
distributor
of
fuel

Injection system
and Digifant ignition (4
valves); Group of
rep. 24; System
injection and ignition
Digifant; Injection part:
restoration

24. Filter to
fuel
◆Position of
montage
arrow
oriented
in the
sense of
flow or
spotting
RUNOUT
and OUT
verse
the front
25. Necklace of
maintenance
26. 20 Nm

Support
For filter
à
fuel
28. Stop
rubber
29. Staple-spring
30. Socket
spacing
31. 10 Nm

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→Fig. 1 Mounting position of the flange

of the fuel discharge unit

The mark on the flange must coincide with the

marker located on the fuel tank.

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4-cylinder injection engine (4 valves), mechanical Page 7 of 7

→Fig. 2 Air vent: control

Lever in rest position: closed

Lever pressed in the direction of the arrow:

open

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Fuel system components: removal and installation

Safety measures during work on the power supply system
Attention
The fuel supply line is under pressure. Before loosening fittings of
flexible, wrap a cloth around the connection point. Then reduce the pressure by unplugging.
cautiously the hose.

When removing and reinstalling the fuel level indicator transmitter or the pump
fuel (fuel discharge unit) on tanks filled entirely or partially, take into account
of the following:

◆Even before the start of the work, the suction pipe of an exhaust gas extraction device
the switch must be placed near the fuel tank mounting opening, in order to
immediately inhale the escaping fuel vapors.
If no exhaust gas extraction system is available, a radial fan must be used.
(the engine is then outside the airflow) having a discharge flow rate greater than 15 m3/h.
Avoid any skin contact with fuel. Wear fuel-resistant gloves.

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Parts of the power supply system: removal and installation

Cleanliness rules
During work to be carried out on the fuel supply/injection system, strictly adhere to the
5 cleanliness rules:

◆Thoroughly clean the connection points and the surrounding area before unscrewing the parts.
◆Place the deposited parts on a clean surface and cover them. Do not use linty cloths.
◆Carefully cover or seal the components that have been opened if the repair cannot be done.
executed immediately.
Only place clean parts:
Remove the spare parts from their packaging just before installation.
Do not use parts that have been kept out of their packaging (e.g. in toolboxes,
etc.).
When the system is open:
Avoid working with compressed air.
Avoid moving the vehicle.

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Fuel system components: removal and installation

Throttle cable: adjustment

→Adjust the throttle cable to

adjusting the notching on the counter bearing
so that the butterfly lever
just reached the full position
gas.

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Power supply system components: removal and reinstallation

Fuel pump unit: removal and installation

Special tools, controllers and auxiliaries

necessary

Wrench for connector nut 3217

V.A.G Torque Wrench 1332 (40 to 200 Nm)

Deposit

First, check if a coded car radio is installed. If so, ask for the anti-theft code number.
Before starting the assembly work, consider safety measures => page20-9
With the ignition off, disconnect the ground strap from the battery.
Remove the trunk floor cover.

Unplug the plug from the flask

connection as well as the pipes
of food and return.
Unscrew the connector nut from the flange
with 3217.
Remove the flange and the sealing ring from
the opening of the fuel tank.
Now loosen the unit of
fuel backflow when turning
to the left to take it out of the
bayonet closure and remove it from the
fuel tank.

Note:

If you want to replace the unit of

fuel backflow, you must
drain the old pumping unit of
fuel before disposing of it.

Rest

The rest of the pumping unit of the

fueling is done in a similar way
in reverse order.

Note:

During the establishment of the unit

fuel backflow, ensure not to
do not bend the indicator transmitter
fuel level.
◆ →When the discharge unit of
fuel is correctly mounted, the
level indicator float
fuel indicated

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4-cylinder injection engine (4 valves), mechanical Page 2 of 2

α = 5°
in relation to the direction of travel A.
Fuel humecting the sealing ring
the flaccid one for the
to climb.
◆Mounting position of the flange
the fuel pumping unit
page20-8, fig.1.

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Power supply system components: removal and installation

Fuel pump: control

Special tools, controllers, and auxiliaries

necessary

Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2

V.A.G 1594 Metrology Adapter Set
V.A.G 1527 diode indicator lamp
◆V.A.G 1715 Multimeter
◆Current flow diagram
◆Nut wrench key 3217
◆V.A.G 1318 manometric device
Adapter 1318/1
Adapter 1318/10
Adapter 1318/11
Graduated glass
V.A.G torque wrench 1332 (40 to 200 Nm)

Control conditions

● The battery voltage must be satisfactory.

Fuse number 18 must be intact.

Conduct of the control

Note:

For the continuation of the work, it may be necessary to disconnect the ground braid from the battery. For this reason,
check if it is a coded car radio. If so, request the anti-theft code number in advance.

Briefly activate the starter.

The activation of the fuel pump must be audible.
briefly -about 1 second-.

If the fuel pump does not start:

Unplug the pump relay

fuel (J17) from the door plate
relay (relay location 12).

Note:

If the relay cannot be extracted from the

relay mounting plate without tools, disconnect at
Prior to that, the battery's ground braid.

Connect the remote control

V.A.G 1348/3A with the cable

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V.A.G 1348/3-2 adapter to contact 4

and to the positive pole (+) of the battery.
Activate the command remotely.

If the fuel pump is working:

Control the relay excitation of

fuel pump

Digifant injection and ignition system

4 valves; Repair group 01;
Self-diagnosis; Actuator diagnostics

If the fuel pump is not working:

Remove the floor cover of

chest.
Unplug the plug from the flange.
found on the fuel tank.

→Connect the LED indicator lamp

V.A.G 1527
with the auxiliary cables of V.A.G
1594 on the
external contacts of the record.
Activate the command remotely.
The light-emitting diode must
turn on

If the light-emitting diode does not light up

not

Search and eliminate the cut of

cable according to the route diagram
current.

If the light-emitting diode lights up

(correct voltage power supply):

Unscrew the flange coupling nut

with 3217.
Check if the electrical cables are
connected between the flange and the pump
fuel.

If no cable cut is found:

Replace the discharge unit of the

fuel.

Power supply: control

Control conditions

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4-cylinder injection engine (4 valves), mechanical Page 3 of 6

The power supply voltage of the pump to

fuel is correct.
Remote command V.A.G
1348/3A is connected.

Conduct of the control

Remove the cap from the nozzle of

fuel tank filling.

Attention
The fuel supply line
is under pressure. Before loosening
flexible couplings, surrounded by a
chiffon the connection point. Reduce
then the pressure by unplugging
carefully the hose.

Unplug the power supply line

in fuel from the distributor of
fuel.

Connect the pressure gauge device

V.A.G 1318
with the V.A.G 1318/10 adapter
on the supply line in
fuel -1-.
Connect the V.A.G 1318/1 hose to
the V.A.G 1318/11 adapter of the device
manometric and keep it in a
graduated glass
Open the stopcock of the device
manometric. The lever is then
orienté dans le sens du débit -A-.
Activate the remote command
V.A.G 1348/3A while closing
slowly the shut-off valve until
what the manometer indicates
3 bar of pressure.
From this moment on, do not modify anymore
the position of
shut-off valve.
Empty the graduated glass.

The pump feed rate of the pump to

fuel is
battery voltage function.
For this reason,
connect the multimeter to the battery
to the vehicle assistance
auxiliary cables of V.A.G 1594.
Remote control the command
pendant
30 seconds
and measure the voltage at the same time

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of the battery.
Compare the amount of fuel
rejected with the value
assigned.

*) Minimum feeding flow rate in cm3/30 s

**) Pressure on the fuel pump, the

engine at a standstill and the pump running
(about 2 volts less than the voltage of the
battery).

Example:

During the check, a voltage of 12.5 volts is

measured on the battery. Given that the
the tension on the pump is about 2 volts more
lower than the battery voltage, there is a
results in a minimum supply flow of 530
cm3/30 s.

If the minimum feed rate is not met:

Check if the fuel lines are not

are not strangled (folds) or
obstructed.

Unplug the supply hose

-1- from the fuel filter inlet.
Using the adapter /10, connect the
manometric device V.A.G 1318 on
the flexible.
Repeat the flow control.

If the minimum supply flow is now

reached

Replace the fuel filter.

Yes, once again, the minimum power supply flow.

not reached:

Drop the discharge unit of

fuel and check if the filter screen
is not clogged.

Only if you have noticed none

default until now:

Replace the discharge unit of the

fuel

If you have achieved the desired flow rate, but

you suspect nonetheless a defect of the
fuel supply system (e.g.

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temporary power failure

Control the current as follows

absorbed by the fuel pump:
Reconnect all the pipes of
detached fuel.

→With the use of the electric pliers,

connect the V.A.G 1715 multimeter to
the red/yellow wire of the wiring.
Start the engine and make it run at
slow down.
Measure the current absorbed by the
fuel pump.
Assigned value: 8 amperes max

Note:

If the disturbance of the power supply system

is only temporary, you can also
carry out control during a course
of trial, but the presence of a second
no one is in this necessary case.

If the value of the absorbed current is exceeded:

Replace the discharge unit of the

fuel.

Fuel pump check valve:

control

Control conditions

● The remote command V.A.G

1348/3A is connected.
●The manometric device V.A.G 1318
is connected.

Conduct of the control

Note:

This control allows for simultaneous verification.

the sealing of the pipe connections
fuel supply from the unit of
fuel backflow to the point of
connection of the manometric device
V.A.G 1318.

Shut off the stopcock of the device

manometric (perpendicular lever)
in terms of flow.
Remote control the command to

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short intervals, until a

pressure of
env. 3 bar
is established.

Attention
Risk of splashes during
the opening of the shut-off valve; maintain
a container in front of the free connection of
manometric device.

If the established pressure is too

important, to lower it by opening with
caution the shut-off valve.
Observe the drop in pressure. After
10 minutes, the pressure should not
fall
below 2 bar.
If necessary, check the seal
the fittings of the pipes or
replace the discharge unit of the
fuel.

If the pressure continues to drop:

Check the tightness of the connections of

drives.

If no defects are detected on the cables:

Replace the discharge unit of the

fuel.

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Parts of the power supply system: removal and reinstallation

Parts of the activated carbon reservoir system: removal and reinstallation

Support
On the dome
of leg of
force D
2. 20 Nm
3. Sheet of
connection
4. Solenoid valve 1
(N80)
◆ The solenoid valve
is excited
(par
impulses
by the device
of order
engine
warm
◆ Control:

Injection system and

Digifant ignition (4
valves); Group of rep.
01; Self-Diagnosis;
Actuator diagnostics

Rubber socket
6. 10 Nm
7. Butterfly valve

8. Conduct
ventilation
Coming from
valve to
gravity of
tank for
fuel
=> page20-
3, position -
6-
9. Reservoir at
activated carbon
Location
assembly:

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4-cylinder injection engine (4 valves), mechanical Page 2 of 2

in the
passage from
front wheel
right
◆ For the
deposit,
drive in
tab of
safety in
the meaning of the
arrow

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Parts of the power supply system: removal and reinstallation

Fuel tank ventilation: control

Special tools, controllers, and auxiliaries

necessary

V.A.G 1390 Hand Vacuum Pump

V.A.G 1368 Depression Meter

Control condition

The ignition contact must be turned off.

Conduct of the control

Remove the air filter.

Digifant injection and ignition system

(4 valves); Repair group 24;
Digifant injection and ignition system;
Injection part: restoration

→Unplug the ventilation hose -1-

of the solenoid valve -2-.
Connect the hand vacuum pump
V.A.G 1390 to flexible -1-.
Disconnect from the activated carbon tank
-4- the ventilation hose -3- of the tank
to fuel and connect it to the
depression meter V.A.G 1368 - connection A-
.
Connect the V.A.G depressometer
1368 -connection B- to the connection of
activated carbon reservoir.
Set the depressometer to position -
B-.
Activate the pump several times.
V.A.G 1390 hand vacuum. Make sure that
what
no depression
does not establish itself.

If depression establishes itself:

Check if the air vent -5- of the

active carbon tank -4- is not
soiled; if necessary, clean it.

If the depression does not set in:

Unscrew the cap of the nozzle of

filling

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of fuel.

Connect the hand-operated vacuum pump

V.A.G 1390 at the depressometer V.A.G
1368 -connector B-.
Set the depressometer to position -
A/B-.
Activate the V.A.G 1390 pump
several times.
No depression
must be established.

If depression sets in:

Check the gravity flap => page

20-3, position -5-
Control the flow of fuel in
the pipe -1- coming from the tank to
fuel.

If depression does not set in:

Screw the cap onto the nozzle of

filling
of fuel.
Operate the pump several times
hand pump V.A.G 1390. Ensure that this
what
no depression
not be established.

Note:

If the fuel level in the tank is

fuel is low, activate the vacuum pump at
main 20 to 30 times at a minimum.

If depression sets in:

Replace the cap of the nozzle

filling
of fuel.

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Exhaust system parts: removal and reinstallation

Exhaust system parts: removal and installation

Note:

After the assembly work done on the exhaust system, ensure to reinstall it without
constraints and to allow enough space relative to the bodywork. If necessary, loosen the
clamping collars and adjusting the silencers in such a way as to maintain sufficient spacing everywhere by
relation to the bodywork and to apply a uniform force to the suspensions.
◆The self-locking nuts must be replaced.

Collector
exhaust, pipe
front exhaust and
catalyst with parts
reported

Joint
Replace
Collector
exhaust
Support
◆ Every
version of
deflector
hot air
5-
correspond
a version
good
determined
the support
4. 20 Nm
5. Air deflector
hot
◆ Different
versions: en
sheet metal and in

source
If the version
is posed
replaced
by the other
version, it
must
also
to ask the
supports
correspondents
-3-.
6. 20 Nm
7. Catalyst

Lambda probe,
55 Nm
Grease

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with "G5"
the threading
only
the 'G5' does not
should not
enter into
contact
with the
mouths of the
body of
probe
◆ Submit and
to rest
with 3337
◆Control:

Injection system and

Digifant ignition (4
valves); Group of
Rep. 24; System
of injection and ignition
Digifant; Sensor and
lambda regulation:
control

9. 40 Nm
Order of
tightening
fig.1
10. Pipe
exhaust
AV1)
O-ring
Replace
12.35 Nm
Tapping ring

14. 30 Nm
15. Measuring tube
of CO
◆Deleted
env. 10.94

Hood
of obstruction

Effective from 10.94

the pipe
the front exhaust is
welded with the
catalyst. In case of
repair, the part must
to be deposited
completely. The pipe
front exhaust as well

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4 cyl. injection engine (4 valves), mechanical Page 3 of 8

that the catalyst

continue to be delivered
individually as
spare parts.

→Fig. 1 Pipe tightening order

exhaust on the manifold
exhaust

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Silent with
suspensions

Note:

In the longitudinal direction, it

the system needs to be adjusted
exhausted in such a way
that the ratings -8-, -11- and -14-
be respected.

40 Nm
Double collar
Intermediate pipe
4. Clamp
5. Central silencer and
going out
◆ Replace
individually
in case of
repair, to
this cutting effect
at a right angle the
pipe of
connection at the point
of cutting
10 - with the saw
of the body shop
V.A.G 1523.
Tie them
silent
central and of
out with a
double necklace
of repair, to
this effect
push the
double necklace

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at ground level
markers -9-.

6. Support
To hold
account
of the
different
versions
=> fig.1
7. 25 Nm
8. Side -c- =10 mm
mini
9. Reference
For necklace
double of
repair
Three times
on the
tour
10. Point of

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cut
11. Side -b- = approx. 5
mm
12. Marker
◆ Three times on
the perimeter
13. Marker
◆ Three times on
the perimeter
the pipe
intermediate
14. Side -a- = about 5
mm
15. Landmark
Three times on
the perimeter
◆ S = BV
mechanics

16. Ring of
retention
17. Suspension
◆ Respect
the position
of
montage
18. 20 Nm
19. Support

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→Fig. 1 Versions of the support

A - Version env. 12.92

B - Version env. 01.93

Note:

Version -B- can also be applied by

complete game on vintage vehicles. A
mixed montage old/new version
is not allowed.

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Digifant ignition and injection system (4 valves) Page 1 of 1

Self-diagnosis
Self-diagnostic

Note:

The self-diagnosis only checks part of the injection and ignition system. For troubleshooting, use in
In any case, the binder "Engine Troubleshooting".

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Self-diagnosis
Operation
The Digifant control unit (J169) for the ignition and injection system is equipped with a memory of
defects.

Any fault affecting the sensors or controlled components is recorded in the fault memory with
indication of the type of anomaly.

The fault memory is limited to 4 slots in memory on version 3.2 of the Digifant. For this reason, 4
a maximum of defects can be memorized simultaneously.

Memory faults can be read using the V.A.G 1551 fault reader or the controller
V.A.G vehicle systems 1552 => page01-6.

Once the defect(s) have been eliminated, the fault memory must be cleared => page01-6.

The faults due to a temporary cable cut or poor contact are also recorded and
reported as follows:

When defects occur for a maximum of 5 seconds, they are only recorded as
temporary (sporadic) faults and marked as such by the suffix 'SP'.
If faults occur for more than 5 seconds, they are recorded and reported as faults.
permanents, even if they do not occur momentarily.

A fault that affects the operation of the lambda regulation can only be queried if:

A test run of at least 5 minutes was conducted; during this time, the temperature of the liquid
Cooling and the oil temperature must rise to above 80°C.
The engine then ran for at least
5 minutes at a slow pace.

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Self-diagnostic
Technical characteristics of self-diagnosis

Equipment

◆Fault memory: permanent memory

◆Fast data transmission

Identification of the control device

=> Page01-4; V.A.G 1551 Fault Reader: connection and selection of the control device for
motor electronics.

Selectable functions

You will find in the table the conditions to be met to be able to select the functions that you
wish.

Function Condition
Engine stopped,
Motor running at
ignition contact
slowdown
wrong
02 Query the defect memory x1) x
Diagnosis of
03 x ---
actuators
04 Start the basic setting --- x2)3)
05 Clear the fault memory x x
06 End the show x x
Read the block of
08 x x
measurement values
09 Read the individual measurement value x x

1) Only when the engine does not start, check the fault memory, the ignition switch.
being put.

2) Only possible when the coolant temperature is above 85°C.

Function previously blocked.

3) Must be carried out after the following work:

Replacement of the control device, the idle stabilization valve, the potentiometer of
butterfly or the butterfly nozzle as well as after the replacement or adjustment of the butterfly switch.

Currently used only for factory checks.

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Self-diagnosis
V.A.G 1551 fault reader: connection and selection of the device
command for the engine electronics

Special tools, controllers, and auxiliaries

necessary

Vehicles 07.93

V.A.G 1551 fault reader with V.A.G cable

1551/1

Vehicles 08.93

◆Lecteur de défauts V.A.G 1551 avec câble V.A.G

1551/3

Note :

Instead of the V.A.G 1551 fault reader, the controller

V.A.G 1552 vehicle systems can be used;

In this case, it is not possible to print the data.

displayed.

Control conditions

●Battery voltage 11 V minimum

Fusible 21 intact

Work process

Vehicles 07.93

→Unclip the socket cover.

diagnostic under the command of
heating-ventilation.
Connect the fault reader (or the
vehicle systems controller) with
the V.A.G 1551/1 cable by proceeding
as follows:
Start by plugging in the black plug
for the power supply of the reader
defects on the diagnostic socket
black.
Plug the white plug into the socket
white diagnostic. (The blue sheet
is not used).

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Vehicles 08.93

Place the ashtray and push it.

diagnostic socket cover towards the
left -arrow-.
Connect the fault reader (or the
vehicle systems controller
the help of the V.A.G 1551/3 cable.

Once the fault reader is connected:

According to the desired function:

Turn on the ignition
or
start the engine => page01-2, Table
Selectable functions.

Note:

◆If the messages described in the

the course of work does not appear
not on screen:

User manual for the fault reader

◆Yes, the text 'Default in the'

data transmission due to
of an error made during the entry
data, unplug the cable from the
defect reader, reconnect it and
restart according to the described procedure
previously.

Use the fault reader while holding

count of displayed instructions:

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Enter code 1 for 'Transmission'

data rapid
Enter the code 01 corresponding to
the address "Engine Electronics" and
validate the entry by pressing the
touch Q.

On the display of the fault reader 037906024AB DIGIFANT 3.0 1463 ⇒

V.A.G 1551 displays the identification of Coding
the control device, e.g.:
◆037 906 024AB = part reference
the control device
DIGIFANT 3.0 = specification of
system and version
◆1463 = technical definition of
program
Coding is not used for the
moment

Press the key⇒.

→Display: Rapid data transmission HELP

Choose the XX function

For the next steps of the procedure, see

descriptions of repairs.

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Self-diagnostic
Fault memory: querying and erasing

Special tools, controllers, and auxiliaries

necessary

V.A.G 1551 fault reader (or V.A.G 1552 vehicle system controller) with
07.93: V.A.G cable 1551/1
08.93: V.A.G cable 1551/3

Work process

Connect the V.A.G 1551 (V.A.G 1552) fault reader and select the control unit for
the engine electronics by entering 'address' 01. The engine should then idle.
V.A.G 1551 Fault Reader: connection and selection of the control device for the electronics
of the engine => page01-4.)
When the control device for the engine electronics manifests, note the version of the device.
of order.

Only if the engine does not start:

Turn on the ignition.

Activate the printer of the fault reader using the Print button. The indicator built into the
the touch must light up.

→Display: Fast data transmission HELP

Choose the XX function

Use the fault reader while holding

count of displayed instructions:
Enter the code 02 corresponding to the
function 'Query the memory of'
"faults" and confirm the entry by pressing
on the Q key.

The number of recorded defects X recognized defects!

No defects recognized!
displayed.
If one or more defects are
memorized:

The recorded defects are displayed and

printed one after the other.

Once the recorded defects Fast data transmission HELP

are printed, the message opposite Choose function XX
est affiché:
Enter the code 05 corresponding to the
function 'Clear the memory of
"defects" and validate the input by pressing

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on the Q key.

Note:

If you have turned off the ignition.

between the functions 'Interrogate the memory of'
defects" and "Clear defect memory", the
The memory of defects is not erased.

→Display: Fast data transmission ⇒

Error memory has been erased!

Press the key⇒.

Enter the code 06 to 'Finish the
data transmission and validate
with the Q key.

Eliminate the flaws printed in you

referring to the defects table
respective.
Digifant 3.0 => page01-17
After eliminating the defects, you
you must complete a trial course
for at least 5 minutes. During this
course
the temperature of liquid
cooling must reach
80°C mini,
the regime must be brought to
3000/min mini
the accelerator must be
briefly pushed in
to the fullest.

After the trial run, it is necessary to do

run the engine at idle for
still at least 5 minutes.
Reinterrogate the memory of
faults of the control device.

If no defect is recorded:

Press the key. ⇒

Display: Fast data transmission HELP

Choose function XX

Enter code 06 to "Finish the

data transmission and validate
with the Q key.

Note:

If the self-diagnosis did not detect any faults,

use the table for further troubleshooting
the corresponding disturbances in the

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Folder 'Engine Troubleshooting'.

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Self-diagnosis
Table of faults of the Digifant 3.0

Note:

The defect tables are classified according to the 5-digit defect code written on the left.
◆Explanations on the types of defects (e.g. "Cut/circuit to ground"):

User manual for the fault reader

If components are reported as defective:

Start by checking the cables and connections by referring to the current flow schematic.
to connectors leading to these components as well as the system's ground cables. Do not replace the
composant que si vous ne constatez alors aucun défaut. Cette précaution vaut en particulier pour les
sporadic defects (SP).

Output on the printer of Possible cause of the defect Remedy

V.A.G 1551
In the presence of a defect:
Continue troubleshooting
according to the table of
No defects recognized! the self-diagnosis did not detect
drawer disturbances
the defect
Engine troubleshooting

Output to the printer of Possible cause of the defect Remedy

V.A.G 1551
00513
Engine speed transmitter The G28 stops working at - Replace G28 =>page24-10,
G28 high regime position -21-
Check the presence of
bad contacts on the cables
Absence of Bad contact in the cables
or the plug connections below
signal of the transmitter
the current flow diagram
Control G28 => page 24-58
00515
Hall transmitter - G40 Defective G40 - Control G40 => page 28-10
No type of
defect
Cable cut
recognized/defect
sporadic

Output on the printer of

Possible cause of the defect Remedy
V.A.G 1551
00518
Throttle potentiometer-G69
Short circuit to ground on the
Short circuit to ground
cables or on G69 Control G69 => page 24-43
Short circuit at the pole
Cable cut
more
G69 defective

Check the presence of

No type of defect Momentarily: interruption of bad contacts on the cables
recognized/defect cable, short circuit or power outage or the connections according to the plug

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sporadic in G69 the course diagram of the

current
Control G69 => page 24-43

Output on the printer of Possible cause of the defect Remedy

V.A.G 1551
00519
G71 in the device of
Pressure transmitter of Replace J169 => page 24-8,
Digifant J169 command
intake manifold -G71 position -11-
defective
Conduct of depression leading to
Control the conduct of
Absence of signal the Digifant control unit
depression
defective, not connected
Check if the behavior of
depression is not tainted by
the oil, replace it if
The oil-engine sucked by
the intermediary of the ventilation of
necessary
If oil is visible
engine plate has arrived by
also in the connection of
pulsations in the line
depression of the device
depression going to the device
order or if the defect
order.
occurs again:
Replace the device of
order
If it is not possible to erase the defect:
Incorrect belt adjustment Control the adjustment of the
cramped timing belt
Wrongly positioned camshaft(s) (1 Control the position of
the tooth is shifted camshaft assembly
If toothed belt adjustment and mounting position of the shafts to
corrects the mistakes
sprockets of the shaft - Check the timing of the
(s) camshafts hot fitted distribution, replace the(s)
with a delay camshaft(s) if necessary

Output on the printer of Possible causes of the defect Remedy

V.A.G 1551
00522
Transmitter of
liquid temperature of Faulty G62 Control G62 => page 24-49
cooling -G62
Cut/
circuit at the pole Cable cut
more
Check for the presence of bad.
No type of
contacts on the cables or the
default Momentarily: cable cut, connections to plug according to the
recognized/defect short circuit or interruption in G62
current flow diagram
sporadic
Check G62 => page 24-49
00523
Transmitter of
air temperature G42 defective Control G42 => page 24-54
admission -G42
Short circuit at the
Short circuit to ground on the cable
mass

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Cut/Short
circuit at the pole Defective G42
more
Cable cut
Check for the presence of bad
No type of
contacts on the cables or the
fault Currently: cable outage, connections to the socket according to the
recognized/defect short circuit or interruption in G42
current flow diagram
sporadic
Control G42 => page 24-54

Output on the printer of the

Possible cause of the defect Remedy
V.A.G 1551
00524
Knock sensor 1 - Cable cut or short circuit on
- Control G61 => page 28-17
G61 the detector cable
G61 defective (detector of
Absence of clicking to the right in the direction of the
- Replace G61 =>page28-4,
signal position -21-
market)
Absence of knock detection - Replace J169 =>page24-8,
by the control device (J169) position -11-
00525
Check the lambda probe and the
Lambda sensor -G39 Defective G39
lambda regulation => page 24-29
Absence of
Cable cut
signal
Short circuit at
Faulty G39
pole plus
Short circuit at the positive pole on the cable

Binder "Current Path Schematics, Electrical Equipment Troubleshooting and Locations of

montage

Output on the printer of

Possible cause of the defect Remedy
V.A.G 1551
00532
Battery voltage above
Power supply voltage Check the alternator
15.5 V
Signal too high
Check the battery
Check the power supply
Weak signal Battery voltage lower than 6.1 V
from the control device => page
24-70
00540
Knock sensor 2 - Cable break or short circuit on
Check G66 =>page28-17
G66 the detector cable
G66 defective (detector of
Absence of clicking to the left in the direction of the
- Replace G66 => page 28-4,
signal position -19-
market)
No detection of clicking by - Replace J169 => page 24-8,
the control device (J169) position -11-
65535
Control device Components of the device - Replace J169 => page 24-8,
defective Digifant command (J169) position -11-

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Self-diagnostic
Defect table of the Digifant 3.2

Note:

The fault tables are classified according to the 5-digit fault code written on the left.
◆Explanations on types of defects (e.g. 'Break/short circuit to ground'):

User manual for the fault reader

If components are reported as defective:

Start by checking, referring to the current flow diagram, the cables and connections.
to boards going to these components as well as the ground cables of the system. Do not replace the
component only if you notice no defects. This precaution is especially valid for the
"sporadic" defects (SP).

Output on the printer of Cause possible of the defect Remedy

V.A.G 1551
In the presence of a defect: Continue troubleshooting according to
No defect recognized! the self-diagnosis did not detect the the table of disturbances of
defect Folder 'Engine Troubleshooting'.
00518
Throttle potentiometer-G69
Power failure/short circuit at Short circuit to ground on the
the mass cables or on G69 Control G69 => page 24-43
Short circuit at the pole
Cable cut
plus
Defective G69

Output on the printer of

Possible cause of the defect Remedy
V.A.G 1551
00519
G71 in the device of
Pressure transmitter of - Replace J169 => page24-8,
Digifant J169 command
intake pipe -G71 position -11-
defective
Conduct of depression leading to
Control the conduct of
Signal not plausible the Digifant control unit
depression
defective, not connected
Check if the driving of
depression is not stained by
the oil, replace it if
The oil engine siphoned by
the intermediary of the ventilation of
necessary
If oil is visible
engine block has arrived by
also in the connection of
pulsations in the pipe of
depression of the device
depression going to the device of
order or if the defect
order.
happens again:
Replace the device of
order
If it is not possible to erase the defect:
Incorrect belt adjustment Check the setting of the
craned timing belt
Poorly positioned camshaft(s) (1 Control the position of

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the tooth is shifted camshaft assembly

If the adjustment of the toothed belt and the mounting position of the shafts
comes correct
Chain sprocket(s) of the shaft Check the timing of the
(s) with hot-fitted cams distribution, replace the(s)
with delay camshaft(s) if necessary

Output on the printer of

Possible cause of the defect Remedy
V.A.G 1551
00522
Transmitter of
liquid temperature of Defective G62 - Control G62 => page 24-49
cooling -G62
Cut/short
circuit at the pole Cable cut
more
Check for the presence of bad
contacts on the cables or the
Signal no Momentarily: cable cut, connections to the card according to the
plausible short circuit or cut in G62
current flow diagram
Control G62 => page 24-49
00523
Transmitter of
air temperature Defective G42 - Check G42 => page 24-54
admission -G42
Short circuit at the
Short circuit to ground on the cable
mass
Cut/short
circuit at the pole Defective G42
plus
Cable cut

Output on the printer of the

Possible cause of the defect Remedy
V.A.G 1551
00524
Knock detector 1 - Cable cut or short circuit on
- Control G61 => page 28-17
G61 the detector cable
G61 defective (detector of
Absence of Replace G61 => page 28-4,
cliquetis à droite dans le sens de la
signal position -21-
market
Absence of knock detection Replace J169 => page 24-8,
by the control device (J169) position -11-
00525
Check the lambda probe and the
Lambda probe -G39 G39 defective
lambda regulation => page 24-29
Absence of
Cable cut
signal
Short circuit at
G39 defective
pole plus
Short circuit at the positive pole on the cable

Folder "Current Flow Diagrams, Electrical Equipment Troubleshooting and Locations of

montage

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Output on the printer of the Cause possible of the defect Remedy

V.A.G 1551
00532
Battery voltage higher than
Power supply voltage Check the alternator
15.5 V
Signal too high
Check the battery
Control the power supply voltage
Signal too weak Battery voltage below 6.1 V
from the control device => page
24-70
00540
Knock detector 2 - Cable cut or short circuit on
- Control G66 => page 28-17
G66 the detector cable
G66 defective (detector of
Absence of clicking to the left in the direction of the
- Replace G66 =>page28-4,
signal position -19-
market)
No click detection by - Replace J169 => page 24-8,
the control device (J169) position -11-

Output on the printer of

Possible cause of the defect Remedy
V.A.G 1551
00740
Detection transmitter
G145 defective - Control G145 => page28-10
of cylinder 1 -G145
Absence of
Cable cut
signal
01087
The motor control device Make the basic adjustment
Basic adjustment not made has not been adapted to the engine =>page24-24
01249
Cable cut or short circuit
in the cables going to the injector of the
Control N30 to N33
Injector cylinder 1 -N301) cylinder 1, 2, 3 or 4
=> page, Injectors: control
Injector of cylinder 1, 2, 3 or 4
(N30 to N33) defective

The display always indicates 'Injector cylinder 1 -N30', even if the fault has occurred on another cylinder.

Exit on
the printer of Cause possible of the defect Remedy
V.A.G 1551
17978
Adapt the control device
the engine electronics for the immobilizer
electronics => page24-72
Check the electronic immobilizer:
The control device of
Control device the electronic anti-theft device (J362) has
Group of rep. 96; Antitheft
the engine is blocked electronics: refurbishment
blocked the Digifant control device
You must then start the
engine and clear the memory of
faults of the control device
Digifant.

Exit on

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the printer
you Possible cause of the defect Remedy
V.A.G 1551
65535
Device of
Components of the control device - Replace J169 => page 24-8, position -
order
Digifant (J169) 11-
defective

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Self-diagnosis
Diagnosis of actuators
The actuator diagnosis allows the activation of the following components, in the order mentioned below:

Fuel pump relay (J17)

2. Idle stabilization valve (N71)

3. Solenoid valve 1 for activated carbon tank (N80)

Special tools, controllers and auxiliaries

nécessaires

◆V.A.G 1551 fault reader (or V.A.G 1552 vehicle systems controller) with
07.93: V.A.G cable 1551/1
08.93: V.A.G cable 1551/3
V.A.G control unit 1598/18
Portable multimeter V.A.G 1526 or multimeter V.A.G 1715
V.A.G 1527 diode indicator lamp
V.A.G 1594 Metrology Adapter Set
V.A.G 1501 measuring cable
Current flow path diagram

Work process

With the ignition contact on, connect the V.A.G 1551 (V.A.G 1552) fault reader and select
the control device for the engine electronics by entering "the address" 01.
V.A.G 1551 fault reader: connection and selection of the control device for electronics
of the engine => page01-4.)

→Display: Quick data transmission HELP

Choose function XX

Use the fault reader while holding

count of displayed instructions:
Enter code 03 for the function
Diagnosis of actuators.

Display: Fast data transmission Q

03 - Actuator Diagnostics

Excite the fuel pump relay (J17):

Validate the entry by pressing the

touch Q.

Display: Diagnosis of actuators ⇒

Fuel pump relay - J17

The fuel pump relay (on the

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relay panel with fuse holder,

relay location 12) must
click until you activate
the actuator by pressing on the
touch

Note:

Pendant l'excitation du relais de la pompe à

fuel

this one must also engage in a way

audible

at intervals.

If the relay does not click:

Control the pump relay to

fuel

Current flow diagrams,

Electrical equipment troubleshooting and
Mounting locations, System
of food

Activate the idle stabilization valve

(N71):

Press the key⇒.

→Display: Actuator diagnostics ⇒

Idle Stabilization Valve - N71

The idle stabilization flap must

click until you
switch the program to
the next actuator by pressing on the
touche

If the idle stabilization flap does not

don't click

Continue the control => page01-27.

Activate solenoid valve 1 for tank at

activated carbon (N80):

Press the key . ⇒

→Display: Diagnostics of actuators ⇒

Solenoid valve 1 reserved. active charcoal -N80

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The solenoid valve (leg dome of

right force) must click until this
that you end the diagnosis of
actuators by pressing the key
⇒.

If the solenoid valve does not click:

Continue the control => page01-29.

Note:

After you have finished the diagnosis

For actuators, you need to enter the code 06.
corresponds to the function 'Finish'
l'émission" et valider cette entrée en appuyant
on the Q key. You must then cut the
ignition contact. If you do not cut the
ignition contact before restarting the
engine, the engine cannot start being
given that the injectors and the transformer
The ignition lights are not activated.

Continuation of the check if the flap of

stabilization of the slow motion does not click:

Deposit the collector's cache

of admission.

Unplug the plug -1- from the flap -2-

and plug in
the measurement cable V.A.G 1501 on the
valve and
the wiring.
Connect the diode indicator lamp
V.A.G 1527
with the V.A.G 1594 adapters
on the forms
1 and 3 of the measuring cable.
The light-emitting diode must
blink rhythmically

If the light-emitting diode flashes:

Continue the diagnosis of

actuators to the end.
Turn off the ignition.
Replace the stabilization flap of the
slow down.

If the light-emitting diode does not blink

step

Continue the diagnosis of

actuators until the end.

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Turn off the ignition.

Connect the V.A.G control unit

1598/18 on the device wiring
order.
Control, according to the diagram of
path of the current, if the cable between the
socket 27 of the control unit and the
contact 3 of the sheet to 3 connections does not
does not present any interruptions.
Cable resistance: 1.5Ω max
Also check if the cable is not
no short circuit at the pole
positive or to the mass of the battery.
Assigned value: ω∞
Control, according to the diagram of
current path, if the cable does not
does not present any interruption between the
contact 1 of the connection to file at 3
fittings and the relay mounting plate.
Cable resistance: 1.5Ω max

If no defect is detected on the cable:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

Continuation of the control if solenoid valve 1

for activated carbon tank not clicking
pas:

→Unplug the plug -1- from

the solenoid valve -2- and connect the lamp
V.A.G 1527 diode tester with the
V.A.G auxiliary cables 1594 to the
unplugged plug.
The light-emitting diode must
to blink

If the light-emitting diode blinks:

Continue the diagnosis of

actuators until the end.
Turn off the ignition.
Replace the solenoid valve.

If the light-emitting diode does not blink

pas:

Continue the diagnosis of

actuators until the end.
Turn off the ignition.

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Connect the V.A.G control unit

1598/18 on the wiring of the device
order.
Control, according to the diagram of
path of the current, if the cable does not
does not present any interruption between the
socket 31 of the control box and the
contact 1 of the sheet to 2 connectors.
Cable resistance: 1.5Ω max
Also check if the cable does not
no short circuit at the pole
positive or to the battery mass.
Assigned value: ∞ω
Control, based on the diagram of
current path, if the cable does not
does not present any break between the
contact 2 of the sheet with 2 connectors and the
relay plate
Cable resistance: 1.5Ω max

If no faults are detected on the cable:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

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Self-diagnosis
Reading the measurement value block and basic adjustment
The measurement values in the functions 'Read block of measurement values' and 'Base setting' will be described.
During the checks of the various components. This table is only intended to provide an overview.

Note:

To change the display group, proceed as follows:

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

higher Press the button 3 Press the key ↑
lower Press the key 1 Press the ↓ key

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Self-diagnosis
Summary table of the display groups of the Digifant 3.0

Display group 00 (decimal display values)

Engine running at idle, control device in 'basic adjustment'
Value correspond
Display Areas
assigned à
1 2 3 4 5 6 7 8 9 10 Engine regime 212...202 770...890/min
Injection duration 5...8 2.5...4.0 ms
Voltage of the potentiometer of
12...49 0.25...0.95 V
butterfly
Probe status counter
0...201) ---
lambda
Lambda regulation hour meter 0 ---
Lambda probe signal 240...100 0...1,0 V
Engine load 60...902) 23...36 %
Coolant temperature 2553 ---
Battery voltage 128...150 12.0...14.2 V
Intake air temperature 73...24 15...50°C

1) The counter rises when the lambda sensor does not emit a signal (e.g. cold sensor). The value can
increase to 127 when, for example, the probe heater or the probe cable are defective. Check
with the function 'Read measurement value block'.

The assigned values are applicable for an altitude of 300 m maximum above sea level.

3) Before initializing the basic setting, the value must be between 4 and 10 (which corresponds to 85...105°C).

Display zones
1 2 3 4
Display Group 01
Value
xxx°C xxxx/min x,xx V xx,xx ms
displayed
Temperature of
Probe tension
Display liquid of Engine regime Injection duration
lambda
cooling
In slow motion,
temperature of
Value 0...1,0 (value
--- --- liquid of
assigned oscillating
cooling 80 °
C mini: 2.5...4.0
Display Group 02
Value
xxx°C xxxx/min xx,x <° xxx %
displayed
Throttle angle
Temperature of calculated value, is
Display liquid of Engine mode function of Motor charge
cooling potentiometer of
butterfly
In slow motion,
--- --- temperature of
Value The ignition contact liquid of

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assigned being set: 0...86 max cooling 80 °

C mini: 23...361)

The assigned values are applicable for an altitude of 300 m maximum above sea level.

Display areas
1 2 3 4
Display group 03
Value
xxx°C xxxx/min xxx°C xx,xx V
displayed
Temperature of
Air temperature Tension de la
Display liquid of Engine regime
of admission battery
cooling
Display Group 04
Value
xxx°C xxxx/min xx,x <° xxx %
displayed
Temperature of
Ignition point
Display liquid of Engine regime Engine charge
(calculated value)
cooling
Slowly,
It is not allowed
temperature of
Value to use this value
--- --- liquid of
assigned to control the point
cooling 80 °
of ignition.
C mini: 23...361)
Display Group 05
Value
xxx°C xxxx/min xx,x <° xx,xx V
displayed
Throttle angle
Temperature of (calculated value, is
Tension of the
Display liquid of Engine regime function of
battery
cooling potentiometer of
butterfly
Value The ignition switch
--- --- ---
assigned being set: 0...86 max

The assigned values are applicable for an altitude of 300 m maximum above sea level.

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Self-diagnosis
Summary table of the Digifant 3.2 display groups

Note:

Only display groups 00 and 01 are shown in the '04 - Basic Settings' function. Even if you
select a higher display group, it is the content of group 01 that is displayed.

Display group 00 (decimal display values)

Engine running at idle, control device in 'basic setting'
Value correspond
Display areas
assigned à
1 2 3 4 5 6 7 8 9 10 Engine regime 212...202 770...890/min
Injection duration 5...8 2.5...4.0 ms
Voltage of the potentiometer of
12...49 0.25...0.95 V
butterfly
Probe status counter
0...201 ---
lambda
Lambda regulation hour meter 0 ---
Lambda probe signal 240...100 0...1,0 V
Engine charge 60...902) 23...36 %
Coolant temperature 4...10 85...105°C
Battery voltage 128...150 12.0...14.2 V
Intake air temperature 73...24 15...50°C

1) The counter increases when the lambda probe does not emit a signal (e.g. cold probe). The value can
increase to 127 when, for example, the sensor heating or the sensor cable is defective. Check
with the function 'Read measurement value block'.

The assigned values are applicable for an altitude of 300 m maximum above sea level.

Display areas
1 2 3 4
Display Group 01
Value
xxxx/min xxx°C x,x V xxxxxxxx
displayed
Temperature of
Probe tension Conditions of
Display Engine regime liquid of
lambda setting2)
cooling
Value
770...890 85...105 0...1,0 (oscillating) 00000000
assigned
Display Group 02
Value
xxxx/min xx,xx ms xx,xx V xxx°C
displayed
Temperature of
Display Engine regime Injection duration Battery voltage
the intake air
Display group 03
Value
xxxx/min xxx % xx,xx <° xxx %
displayed
Throttle angle
(calculated value, is Opening of the

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function of valve of
Display Engine regime Engine load potentiometer of stabilization of
butterfly slow down
in slow motion, in slow motion,
temperature of temperature of
Value the ignition switch
--- liquid of liquid of
assigned set: 0...86 max
cooling of 80 cooling of
363. . .32 : i n m
iC° 80°Cmin: 7...25

The assigned values apply to the control device in basic setting.

2) Meaning of the 8-digit block numbers => page01-38.

The assigned values are applicable for an altitude of 300 m max above sea level.

Display zones
1 2 3 4
Display Group 04
Val. aff. xxxx/min xxx % xxx xxxxxxxx
State of
Display Engine regime Engine load Without meaning
operation
in slow motion, Meaning of the
Value liquid temperature numbers in the block
--- ---
assigned cooling of 8 digits
80°C min: 23...361) => page01-38.
Display group 05
Value affair. xxxx/min xxx % xxx xxxxxxxx
Cyclical report
of solenoid valve 1 from Signal of
Display Engine regime Without meaning
coal reservoir consumption
active
in slow motion,
Value liquid temperature
--- --- ---
assigned of cooling
80°C min: 0...23

The assigned values are applicable for an altitude of 300 m maximum above sea level.

Display zones
1 2 3 4
Display group 06
Value
xxx xxx xxx xxx
displayed
The stored value
Value Value during the adjustment of
Adaptive value for the
Display of the integrator of the integrator base for the position of
slow motion stabilization
lambda1) lambda1) throttle potentiometer
closed butterfly
Value
if 0 so 0...70 8...48 24...98
assigned
yes 255 so 144...255
Display group 07: only scheduled for factory inspections.

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1) You must always take into account the values displayed in areas 1 and 2:

If zone 1 displays a 0, zone 2 must indicate a value between 0 and 70.

If zone 1 shows 255, zone 2 must indicate a value between 144 and 255.

Meaning of the 8-digit block numbers

Meaning when display numbers = 1

Adjustment Conditions Operating status
x x x x x x x x
(Display Group 01) (Display Group 04)
Default stored in the
1 Deceleration
memory of defects
1 Without meaning Idle
Compressor of
1 air conditioner turned on
Partial charge
Idle switch
1 Full load
open
Defect in regulation
1 Without meaning
lambda
1 Open butterfly Without meaning
Superior regime to
1 Without meaning
2500/min
Coolant temperature.
1 Without meaning
below 80°C

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Digifant ignition and fuel injection system

Digifant ignition and injection system

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Digifant ignition and injection system

Overview of mounting locations

Air Intake Temperature Sensor (G42)

2. Solenoid valve 1 of the activated carbon tank (N80)
◆ Activated carbon tank system

Repair group 20, Fuel system parts: removal and installation, Fuel system parts
activated carbon tank: removal and reinstallation

3. Connection to a 4-way connector

◆ For lambda probe (G39)
4. Throttle potentiometer
(G69)
5. Idle switch (F60)
Spark plug, 30 Nm
◆=>page28-2

7. App. of
order of
system
of ignition and
injection
Digifant (J169)
8. Measuring tube
of CO
9. Connection of
mass
◆Pour
indicator
multifunction
10. Lighter
◆=>page28-2
11. Transformer
ignition (N152)
◆ =>page28-3
12. Transmitter of
temperature of
liquid of
cooling
(G62)
13. Connection to file
at 5 connections
◆Pour
injectors
14. Connection to sheet
central
15. Connection to file
for 3 connections
For
detector of
clicks 2
Noir
On the
support, au

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environment

16. Transmitter of
engine mode
(G28)
17. Connection to sheet
to 3 connections
◆Pour
transmitter
of regime
engine
On the
support, en
base
18. Connection to file
with 3 connections
◆ For
detector of
clicks 1
Marron

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On the
support
above
19. Connection of
measure
◆ For
measure of
the pressure
you
fuel
20. Detector of
clicks 2 (G66)
◆=>page
28-4
21. Valve of
stabilization of
slowdown (N71)
22. Regulator of
pressure of
fuel
23. Flap of
regulation of
pressure for
aeration of
engine cover

24. Distributor of
fuel
With
injectors
(N30 to
N33)
25. Detector of
clicks 1 (G61)
◆ page
28-4
26. Tank at
activated carbon
◆Under the
air filter
System
of
reservoir to
coal

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active

Repair group
20, System parts
of food: removal and
rest, Items of
tank system
activated carbon: deposit and
rest

27. Regulator of
temperature
◆ For
warming
air
of admission

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Digifant ignition and injection system

Injection part: refurbishment
Ignition part: restoration

Repair group 28

Note:

The control device of the ignition and injection system is equipped with a self-diagnostic system.
Before carrying out repairs and for troubleshooting, one must start by questioning the memory.
of defaults. It is also necessary to check the hoses and vacuum connections (parasitic air).
The components marked with the symbol * are controlled
by self-diagnosis.
=> page01-6, Memory of defects: questioning
◆You can control the components marked with the ** symbol using actuator diagnostics.
=> page01-24.
A minimum voltage of 11.5 V is essential for
proper functioning of the components
electric.
If, after troubleshooting, repairing, or inspections, the engine only starts briefly,
Stops, this may be due to the fact that the anti-theft system is blocking the engine control device.
Then query the fault memory and, if necessary, adjust the control device => page24-71.
Do not use silicone sealant products.
The silicone particles drawn in by the engine do not
are not burned in the engine and damage the
lambda probe.
◆The flexible connections are secured with spring clamp collars or tightening collars.
◆Systematically replace the clamp collars with spring clamp collars.

Security measures => page 24-21

Cleanliness rules => page 24-22

Technical Specifications => page24-23

Admission system: leak test (air leakage)

=> page24-82

Air filter
Disassemble
and assemble
=> page24-
18
2. Sheet of
connection
3. Air intake
hot
By the
deflector
hot air
on the
collector

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exhaust
Connection pipe
Flexible
of admission
6. Conduct of
depression
7. Towards the solenoid valve
1 from reservoir to
activated carbon (N80)
System of
tank to
activated charcoal

Repair group
20, System parts
of food: deposit and
rest, Parts of the system
from coal reservoir
active: drop and repose

8. Sheet of
connection
◆ Unplug
you connect
the
card, the
contact
ignition
being cut off

9. Support
10. 10 Nm
11. Device of
Digifant command
(J169)*
◆ For system
injection,
regulation
lambda
regulation of
clicking,
limitation of
diet
lighting and
self-diagnostic
◆ With
transmitter
of pressure

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of the tubing
of admission
(G71)*
◆Control
the food
under tension
page24-69
◆ Control the
incoming signal
of the starter
=> page24-73
Location
the assembly: to
straight in the
water caisson
In case of
replacement
perform a
adjustment of
base => page
24-24
Vehicles
10.94
In case of
replacement
the device of
command must
to be adapted to
the anti-theft system
electronics
=> page24-71

Flexible from
depression
13. 20 Nm
14. Upper part of
collector
of admission
◆ To tighten it
first on the
part
lower,
then fix it
on the
supports
Dismantle
and assemble
=> page24-
13
15. Transmitter of

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temperature of
liquid of
cooling
(G62)*
◆ White
◆Before the
deposit,
lower if
necessary the
pressure of
system of
cooling
Control
=>page24-49
Values of the
resistance
=>page24-20,
fig.1
Joint
Replace
17. Lower part of
collector
of admission
Disassemble
and assemble
=> page24-16

18. Support
To connect to
card with 5 connections
Support rings
20. O-ring
◆ Replace in case
of damage
21. Speed transmitter
engine (G28)*
For the
replacement
put down the console
22. Flexible power supply
◆Brake with a
blade collars
spring
◆ Black, the case

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benchmark
white
Coming from the unit
food supply in
fuel in
the tank for
fuel
23. Flexible return
◆Brake with a
blade collars
spring
Blue or reference
blue
Towards the reservoir
to fuel

24. Cache
25. Regulation valve
pressure for
ventilation of the casing
engine
26. Lambda probe (G39)
* , 55 Nm
◆ Location
the assembly:
in the pipe
exhaust
before
Grease with
the 'G5'
threading
only; the
"G5" must not
do not enter

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contact with
the slits of the
body of
probe
◆ Control the
probe
lambda and the
regulation
lambda
=> page24-
29
◆ 07.94:
food
under tension of
heating of
the probe via
the relay of
heating of
the probe
lambda
(J278)
Control
the food
in tension
=> page24-
34
◆Control the
continuity
electric of
heating of
probe

27. Connection to
card at 4
fittings
◆ For
probe
lambda and
heating
of the probe
28. Flexible of
connection
Pipe of
connection
with
element
heating
for
some
country

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export.
29. Ring of
fixation

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Digifant ignition and injection system

Upper part of the intake manifold: disassembly and assembly

10 Nm
2. Throttle nozzle
After
replacement
Adapter
the device of
order
Digifant at
engine. At this
effect, carry out
a setting of
base
=> page24-24
3.3 Nm
4. Contactor of
slow (F60)
◆ Control
=>page24-62
◆ Replace and
to settle
=>page24-67
5. Joint
◆Replace

6. Counter-bearing
◆ For cable
of the accelerator
◆ Settle the
cable
of the accelerator

Reply group 20;

System parts
of food: removal and
repose; Câble
accelerator: adjustment

7. Upper part of

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collector
of admission
8. Socket in
rubber
Support ring
◆ For flap
of
stabilization
you
slow down
10. Support
For valve
of
stabilization
you
slow down
11. Valve of
stabilization of
slowdown (N71)**
Resistance:
3.5 to 4.5Ω
Only
Digifant 3.2:
◆Control the
stabilization
you slow down
=>page24-
36

12. Flexible connector

13. Fitting of
depression
For regulator
of pressure of
fuel
14. Potentiometer of
butterfly (G69)*
◆ Control
page24-43
◆ Golden contacts
◆After
replacement
Adapter
the device of
order
Digifant at
engine. At this

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effect, carry out a

basic setting
=> page24-24
15. O-ring
◆ Replace in case
of damage

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Digifant ignition and injection system

Lower part of the intake manifold: disassembly and assembly

Injector (N30 to N33)

◆Control => page
24-75
◆ Resistance: 15 to
20ω
◆ Position of
montage
the hollowing on
the injector - arrow
A- must coincide
with the nipple on the
distributor of
carburant -flèche
B-
Retention clip
3. O-ring
◆ Replace in case
damage
4. Pressure regulator
you
fuel
◆Control the
regulator of
pressure and the
pressure of
retenue => page
24-79
5. Shutter
◆ For connection of
measure
To remove it, the
compress on the
sides - arrows -

6. 10 Nm
7. Upper part of
distributor of
fuel
◆ With guide
cable
8. Lower part of
distributor of
fuel
9. Lower part of
collector
of admission
10. O-ring
Replace in

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case
of damage

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Digifant ignition and injection system

Air filter: disassembly and assembly

Rubber protector
2. Air filter cartridge
3. Upper body of
air filter
4. Regulator of
temperature
For reheating
of the intake air
◆Tubing of
metal fitting
or with notch
towards the window
of regulation
◆ Control the
air warming
of admission
=>page24-84
5. Transmitter of
air temperature
admission (G42)*
◆Contrôler => page
24-54
Values of the
resistance
=>page24-20, fig.
1
6. O-ring
◆Replace in case
of damage

Retention clips
8. Joint
◆Replace in case
damage
9. Stopper
10. Management of depression
11. Support
12. Lower body of the filter
to have

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→Fig. 1 Values of resistance for

The diagram relates to the transmitter of

coolant temperature
(G62) and to the air temperature transmitter
of admission (G42).

Part A indicates the resistance values

for the temperature range of 0 to 50°C, the
part B indicates the values for the range of
temperature 50 to 100°C.

Examples:

◆30°C corresponds to a resistance of

1500 to 2000Ω
◆80°C corresponds to a resistance of

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275 to 375 ohms

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Digifant ignition and injection system

Security measures
Attention
The supply system is under pressure. Before loosening any hose fittings or opening
the control connection, wrap a cloth around the connection point. Then reduce the pressure in
carefully unplugging the hose or, if applicable, the sealing cap.

To avoid any bodily harm and/or damage to the ignition and injection system, take this into account.
who follows :

Do not touch or unplug the ignition cables when

the engine is running or is at its starting regime.
Do not disconnect and reconnect the system cables
of ignition and injection - including the cables of the devices
measuring - only when the ignition contact is off.
If the engine must run at launch speed without
that there is a start, e.g. for monitoring the rate of
unplug the plug connection
speed transmitter (on the cylinder head support,
bottom left.

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Digifant ignition and injection system

Rules of cleanliness
When carrying out work on the fuel supply/injection system, strictly adhere to the
5 rules of cleanliness are as follows:

◆Thoroughly clean the connection points and the surrounding area before unscrewing the parts.
◆Place the deposited parts on a clean surface and cover them. Do not use linty cloths.
◆Carefully cover or seal the components that have been opened if the repair cannot be done.
executed immediately.
Only place clean pieces:
Remove the spare parts from their packaging just before installation.
Do not use parts that have been stored outside their packaging (e.g. in toolboxes,
etc.).
When the system is open:
Avoid working with compressed air.
Avoid moving the vehicle.

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Digifant ignition and injection system

Technical characteristics

Reference letters engine ABF

Idle regime 1/min 770...8901
CO2 content % in flight. 0.3...1.21)
Digifant3 control device
Digifant version 3.0 3.2
Reference part4) 037 906 024-/AB 037 906 024 AE
Limitation of the regime 1/min 7000

Updated values:

Folder Anti-Pollution Service

is not adjustable

3) In case of replacement, perform a basic adjustment => page 24-24

4) Current reference, see Parts Catalog

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Digifant ignition and injection system

Basic setting: process

Note:

With the basic setting, the Digifant control unit is adapted, at idle, to the potentiometer.
from the butterfly, to the idle speed stabilization flap and to the engine.

Special tools, controllers and auxiliaries

necessary

◆V.A.G 1551 fault reader (or V.A.G 1552 vehicle systems controller) with
07.93: V.A.G cable 1551/1
08.93: V.A.G cable 1551/3
V.A.G ignition controller 1767 or V.A.G 1367 with
V.A.G impulse pliers 1367/8

Control conditions

●Engine oil temperature: 80°C minimum

●Unplugged electric consumers (the radiator fan must not operate during the
control
Air conditioner out of order
Correct throttle cable adjustment

Repair group 20; Fuel system component: removal and installation; Throttle cable: adjustment

Conduct of the control

Disconnect the ventilation hose from the

carter-engine -1- of the valve of
pressure regulation -2- and the installation of
such a way that only fresh air
can be sucked.

Connect the ignition controller

V.A.G 1767
or the V.A.G 1367 ignition controller

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help
from the impulse pliers V.A.G1367/8.
Query the memory of defects; if
necessary
eliminate the existing defects and erase
then
the memory of defects.
=> page01-6, Memory of defects:
questioning and erasure

Note:

The control takes place differently for the

Digifant 3.0 and Digifant 3.2. Ask for it
controller version => page
01-4; V.A.G 1551 Fault Reader:
connection and selection of the device
command for the engine electronics.

Then:
Keep the player plugged in
flaws
V.A.G 1551.
Let the engine run at
slow down.

→Display: Fast data transmission HELP

Choose the function XX

Enter the code 04 corresponding to the

function "Start the basic setting"
and validate the entry by pressing the
touch Q.

Display: Basic setting HELP

Enter display group number XX

Suite for the Digifant 3.0 (09.94)

(continuation for Digifant 3.2 => page 24-27)

Enter the code 00 corresponding to

Display group number
validate the entry by pressing the
touche Q.

Display: System in basic setting 0 ⇒

(1 to 10 = display zones) 1 2 3 4 5 6 7 8 9 10

Check the ignition timing at

2000...2500/min.
Control value: 4 to 8° before
PMH1)

Updated values:

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Pollution Control Service Folder

Let the engine idle

for at least
1 minute.
Read the lambda probe signal
in the display area 5.
The display must
fluctuate from
more than 30.
Terminate the default settings of
motor by actuation
from the button⇒. The fan of the
the radiator must not
function.
Press the key. ⇒
Enter the code 06 to "Finish the
data transmission and validate
with the Q key.

If the assigned values are not met:

Check the system's tightness

admission (air parasite)
=> page24-82.
Check the system's tightness
exhaust between
the cylinder head and the catalyst, tube of
CO measurement
understood.
Check the lambda sensor and the
lambda regulation
=> page24-29.
Carry out a test drive,
re-interrogate the memory of
defaults and repeat the basic setting.

Suite for the Digifant 3.2 (10.94)

Enter the code 01 corresponding to

Display group number
validate the entry by pressing the
touche Q.

Display: Basic setting system 1 ⇒

(1 to 4 = display areas) 1 2 3 4

Only continue the control once that

00000000 is displayed in the 4th zone
of the 8-digit display block.

Note:

Yes, in display area 4, a 1 is displayed

in one or more places, the conditions of

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controls are not fulfilled.

Meaning of the numbers of

block of 8 digits

Check the ignition timing at

2000...2500/min.
Control value: 4 to 8° before
PMH1)

Updated values:

Binder Anti-Pollution Service

Run the engine at idle

for at least
1 minute.
Read the lambda tension in the area
of display 3.
The lambda tension must
fluctuate from
more than 0.3 V.
Stop the basic settings of the
motor by actuation
from the button ⇒. The fan of the
radiator should not then
function
Enter the code 06 to 'Finish the
data transmission" and confirm
with the Q key.

If the assigned values are not reached:

Check the system's tightness

of admission (air parasite)
=> page24-82.
Check the leak tightness of the system
exhaust between
the cylinder head and the catalyst, tube of
CO measurement
understood.
Check the lambda probe and the
lambda regulation.
Conduct a trial run,
re-interrogate the memory of
defaults and repeat the basic setting.

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Digifant ignition and injection system

Lambda probe and regulation: control

Special tools, controllers, and auxiliaries

necessary

◆V.A.G 1551 fault reader (or V.A.G 1552 vehicle system controller) with
07.93: V.A.G cable 1551/1
08.93: V.A.G cable 1551/3
◆CO Analyzer V.A.G 1363 A or
4 gas analyzer V.A.G1788
◆V.A.G adapter 1363/3
◆V.A.G 1598/18 control unit
Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
V.A.G 1594 Metrology Adapter Set
Current flow diagram

Control conditions

● Basic correct setting

●Waterproof exhaust system between the catalyst and
the cylinder head

Conduct of the control

Connect the V.A.G 1551 (V.A.G 1552) fault reader and select the control device.
the engine electronics by entering "the address" 01. The engine must then idle.
V.A.G 1551 fault reader: connection and selection of the electronic control device
moteur => page01-4.)
When the control device for the engine electronics manifests, note the version of the device.
of order.

Display: Fast data transmission HELP

Choose the function XX

Enter the code 08 corresponding to the

function "Read block of values from
measure" and validate the input by pressing
on the Q key.

→Display: Read measurement value block HELP

Enter display group number XX

Enter the code 01 corresponding to

"Display group number" and
validate the entry by pressing the
touche Q.

Display: Read measurement value block 1 ⇒

(1 to 4 = display areas)

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1 2 3 4

Only proceed with the control when:

● the temperature of the liquid

Cooling is above 80°C
Digifant 3.0 = display zone 1
Digifant 3.2 = display zone 2
the engine then ran for
another 2 minutes
in slow motion

→With the V.A.G1363/3 adapter,

connect the V.A.G CO analyzer
1363A or the V.A.G 1788 4 gas analyzer
on CO measurement tube.
Control the CO content.
Assigned value: 0.3 to 1.2% by volume.
Take into account the tension of the
lambda sensor indicated in the area
display 3. The voltage must
fluctuate at least 30 times per minute
on a beach of
0 to 1.0 V.

If the voltage varies less frequently,

search for the origin of the defect => page 24-34

Update for the Digifant 3.0 (09.94)

Unplug the vacuum hose

-1- of the connecting nozzle -2-. The
the tension of the probe must
increase then
fall again
to the old value.

Reconnect the vacuum hose -

1-. The probe tension must
to fall
then
to go up
à l'ancienne valeur.

Continuation for the Digifant 3.2 (10.94)

Disconnect the 2-plug connector -1-

of the temperature transmitter of
coolant (G62) -2-. The
the tension of the probe must

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increase
and fall back
to the previous setting beach.
Reconnect the plug. The voltage of the
probe must
fall
and go back up
at the previous beach.

Note:

During the inspection, the engine speed must not

increase to more than 1500/min, otherwise the sheet
disconnected from the control unit would be
detected as a defect.

Suite for the Digifant 3.0 and the Digifant 3.2

Press the key⇒.

Enter code 06 to "Finish the
data transmission and validate
with the Q key.
Cut off the ignition contact.

If no regulation has been detected:

Control the heating of the probe

lambda => page24-34.

→Connect the V.A.G control unit

1598/18 on the wiring of the device
order.

Unplug the 4-pin connector

fittings going to the lambda probe -1-.
Control, based on the scheme of
current path, if the cables between
the control box and the 4-pin plug
connectors do not have any

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cuts
Contact 3 + socket 42
Contact 4 + socket 20
Cable resistance: 1.5Ω max
Control, based on the diagram of
current course, if the cables on the
the sheet with 4 connectors does not show any
courts-circuits between each other.
Assigned value: ∞ω
Control, according to the scheme of
current path, if the cable of
shielding - control box, socket 65
does not present short circuits
towards the cables of the probe.
Assigned value: ∞ω

If no defect is detected:

Replace the lambda sensor (G39).

Possible causes of the defect when the

the regulation frequency of the probe is
too slow

The slits or holes in the head of

the probes are
obstructed
The ventilation hole on the probe, at
The level of the connection cable is
obturated
◆The probe underwent too much
thermal solicitation
vitrification
The probe was damaged by some
fuel
with lead

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Digifant ignition and injection system

Lambda sensor heating: control

Special tools, controllers, and auxiliaries

necessary

V.A.G 1598/18 control unit

Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
◆ V.A.G 1594 Metrology Adapter Set
◆Current flow diagram

Control condition

Fuel pump relay in good condition

Control the power supply

Unplug the 4-pin connection

connectors -1- of the lambda sensor.
To measure the voltage, connect the
multimeter at contacts 1+2 of the connector.
Start the engine.
Assigned value: 11 V min
Turn off the ignition.

In the absence of tension:

Connect the V.A.G control box

1598/18 on the device wiring of
order.
Turn on the ignition.
Shunt the sockets 1+6 of the box
control using auxiliary cables
from V.A.G 1594 (the fuel pump
must work).

07.94:

Shunt the sockets 1 + 28 of the

control box. The relay of
lambda sensor heating must
commuter.

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Take into account the display on the

multimeter.
Assigned value: 11 V min

If the assigned value is not reached:

Check the cable connections in

fonction du schéma de parcours du
current.

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Digifant ignition and injection system

Slow motion stabilization: control

This control concerns only the Digifant 3.2 (10.94)

(To query the version of the control unit => page01-4; Fault reader V.A.G 1551:
connection and selection of the control device for the engine electronics.

Special tools, controllers, and auxiliaries

necessary

V.A.G 1551 fault reader or V.A.G 1552 vehicle systems controller with V.A.G 1551/3 cable

Control conditions

● Basic correct adjustment

Coolant temperature: 85°C minimum

Conduct of the control

Functioning: control

Control the operation => page01-24, Actuator diagnostics.

Regulation: control

Connect the V.A.G 1551 (V.A.G 1552) fault reader and select the control unit of
the engine electronics when entering "the address" 01. The engine should then idle.
V.A.G 1551 fault reader: connection and selection of the electronic control device
engine => page01-4.)

Display: Fast data transmission HELP

Choose the function XX

Enter the code 08 corresponding to the

function "Read block of values from
"Measure" and validate the entry by pressing
sur la touche Q.

Display: Read measurement value block HELP

Enter display group number XX

Enter the code 08 corresponding to the

function 'Read block of values from
measure" and validate the entry by pressing
on the Q key.

Display: Read measurement value block 3 ⇒

(1 to 4 = display zones) 1 2 3 4

Idle the engine

for at least

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1 minute.
Read the value indicated in the area
of display 4.
Assigned value: 7 to 25 %
(idle speed 770 to 890/min)
Press the key ⇒.
Enter the code 06 to "Finish the
data transmission" and validate
with the Q key.

If the assigned value is exceeded:

Check the tightness of the system

of admission
=> page24-82.
Replace the stabilization flap of the
slowdown
=> page24-14, position -11-.
Replace the control device
Digifant (J169)
=> page24-8, position -11-.

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Digifant ignition and injection system

Enrichment at acceleration/full load and power cut in
deceleration: control

This control only concerns the Digifant 3.0 (09.94)

(To query the version of the control device => page01-4; Fault reader V.A.G 1551:
connection and selection of the control device for the motor electronics.

Note:

The following control allows checking the power cut during deceleration. If this control is satisfactory,
The enrichment at acceleration and full load is also correct.

Special tools, controllers and auxiliaries

necessary

◆V.A.G 1551 fault reader (or V.A.G 1552 vehicle system controller) with
07.93: V.A.G cable 1551/1
08.93 : V.A.G cable 1551/3

Control condition

● Coolant temperature: 80°C min

Conduct of the control

Connect the fault reader V.A.G 1551 (V.A.G 1552) and select the control unit of
the engine electronics by entering "the address" 01. The engine should then idle.
V.A.G 1551 fault reader: connection and selection of the electronic control device.
engine => page01-4.)

Display: Fast data transmission HELP

Choose the XX function

Enter the code 08 corresponding to the

function 'Read block of values from
"measure" and validate the input by pressing
on the Q key.

→Display: Read measurement value block HELP

Enter display group number XX

Enter code 01 corresponding to

"Numéro de groupe d'affichage" et
validate the entry by pressing the
touch Q.

→Display: Read block of measurement values1 ⇒

(1 to 4 = display areas) 1 2 3 4

Raise the indicated value in the

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display zone 4.
Increase the engine speed by a
accelerator kick at approx. 4000/min
(=> display area 2) and release the
accelerator command. The value
indicated in display area 4
(injection duration) must
increase, fall back to 1.50 ms, then
to go back up
at the previously noted value.
Press the key . ⇒
Enter the code 06 to "Finish the
data transmission and validate
with the Q key.

If the displayed value does not increase and does not

do not fall back to 1.5 ms either:

Interrogate the memory of defects; if

necessary
eliminate the existing defects and
then erase
the memory of defects.
=> page01-6, Memory of defects:
interrogation and erasure
Check the throttle potentiometer
=> page24-43.
Check the idle switch =>
page24-62.

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Digifant ignition and injection system

Engine operating states: control

This control concerns only the Digifant 3.2 (10.94)

(To query the version of the control device => page01-4; V.A.G 1551 fault reader:
connection and selection of the control device for the engine electronics.

Note :

The control consists of determining whether the Digifant control unit (J169) recognizes the states of
engine operation (idle, partial load, full load, deceleration).

Special tools, controllers, and auxiliaries

necessary

V.A.G 1551 fault reader or V.A.G 1552 vehicle system controller with V.A.G 1551/3 cable

Control condition

● Coolant temperature: 80°C min

Procedure of the control

Connect the V.A.G 1551 (V.A.G 1552) fault reader and select the control device.
The motor electronics when entering "the address" 01. The motor should then run at idle.
V.A.G 1551 fault reader: connection and selection of the electronic control device
engine => page01-4.)

Display: Fast data transmission HELP

Choose function XX

Enter the code 08 corresponding to the

function 'Read block of values from'
measure" and validate the input by pressing
on the Q key.

Display: Read measurement value block HELP

Enter display group number XX

Enter the code 04 corresponding to

"Display group number" and
validate the entry by pressing the
touch Q.

→Display: Read block of measurement values4 ⇒

(1 to 4 = display areas) 1 2 3 4

Take into account the display area 4 -

block of 8 digits-:
The 4 positions on the right are without
meaning

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Display in operating condition

Idle:

The 2nd position from the left must

indicate a 1.
Display: 01000000

◆Partial charge:

Accelerate gradually.

The 3rd position from the left must

indicate a 1.
Display: 00100000

◆Full charge:

Accelerate to the max (full throttle).

The 4th position from the left must

briefly indicate a 1.
Display: 00010000

◆Deceleration:

Make the diet exceed

3000/min.
Close the butterfly in one go.

The 1st position from the left

must indicate a 1 as long as the regime
is greater than 1500/min
Display: 11000000 (briefly)

Note :

Below 1500/min, the idle is

newly recognized.

Press the key ⇒.

Enter the code 06 to 'Finish the
data transmission and validate
with the Q key.

If the assigned values are not reached:

Interrogate the fault memory; if

necessary
eliminate the existing defects and
then erase
the memory of faults.

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=> page01-6, Memory of defects:

interrogation and erasure
Check the throttle potentiometer
page 24-43
Check the idle switch =>
page24-62.

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Digifant ignition and injection system

Throttle potentiometer: control

Special tools, controllers, and auxiliaries

necessary

V.A.G 1551 fault reader (or V.A.G 1552 vehicle system controller) with
07.93: V.A.G cable 1551/1
08.93 : V.A.G cable 1551/3
◆V.A.G control unit 1598/18
◆Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
◆V.A.G 1594 Metrology Adapter Set
Current flow schematic

Conduct of the control

With the ignition contact on, connect the V.A.G 1551 (V.A.G 1552) fault reader and select
the control device for the engine electronics by entering "address" 01.
(V.A.G 1551 fault reader: connection and selection of the control device for the electronics
of the engine => page01-4.)
When the control device for the engine electronics is displayed, note the version of the device.
of order.

Display: Fast data transmission HELP

Choose function XX

Enter the code 08 corresponding to the

function "Read block of values from"
measure" and validate the entry by pressing
on the Q key.

→Display: Read measurement value block HELP

Enter display group number XX

Enter the "Group Number"

of display" and confirm the input in
pressing the Q key:
Digifant 3.0 = 02
Digifant 3.2 = 03

Display: Read measurement value block 2 (3) ⇒

(1 to 4 = display areas) 1 2 3 4

Read the butterfly angle in the area.

display 3.
Assigned value: 0 <°
Slowly open the butterfly until the
about, while observing the indicated angle
in the display area 3.
The numerical value must
regularly increase throughout the
beach.

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Note:

The displayed value depends on the tolerances of the

throttle potentiometer and does not match
not at the actual opening angle. The value
the allowable display must not exceed
86 <°.

If the value does not increase regularly:

Replace the throttle potentiometer

(G69).

If the display is constantly 0 <° or about.

90 <°:

Pursuit
Display Cause you
control
Break or
=> page
0 <° short circuit at the
24-46
mass
Short circuit at => page
env. 90 <°
more pole 24-47

Continuation of control if the display is 0

<°:

→Unplug the 3-prong plug -1-

the throttle potentiometer -2-.
Shunt the 1+1 contacts of the connector
with the auxiliary cables of V.A.G
1594 and pay attention to the display.

Display 90 <°:

Replace the throttle potentiometer

-2-.

Display 0 <°:

Measure the voltage on the plug between the

contacts 1+3.
Assigned value: approx. 5 V
Press the key ⇒.

Enter the code 06 to "Finish the

data transmission" and validate
with the Q key.
Turn off the ignition.
Connect the V.A.G control unit
1598/18 on the device wiring

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order.

In the presence of a voltage of approx. 5 V:

Control, according to the scheme of

current route, if the cable does not
does not present any interruptions between the
socket 40 and pin 2 of the 3-pin plug
connections.
Cable resistance: 1.5Ω maxi
Also check if the cable is not
does not present any short circuits at the
mass.
Assigned value: ω∞

In the absence of tension:

Control, based on the diagram of

current path, if the cable does not
does not have interruptions between the
socket 41 of the control box and the
contact 1 of the sheet to 3 connections or
between socket 33 and contact 3.
Cable resistance: 1.5Ω max

If no defect is detected on the cables:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

Continuation of the control if the display is approx.

90 <°:

Unplug the 3-pin plug -1-

the butterfly potentiometer -2-.

Display 0 <°:

Replace the throttle potentiometer

-2-.

Display 90 <°:

Measure the voltage on the plug between the

contacts 1+2 and note it.
Press the key⇒.
Enter the code 06 to "Finish the
data transmission" and validate
with the Q key.
Turn off the ignition.
Unplug the device's plug from
order
Digifant.

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In the presence of a voltage of approx. 5 V:

Control, according to the diagram of

current path, if the cables to
contacts 1+2 of the sheet to 3 connections
do not present short circuits
among them.

If the voltage corresponded to approx. the voltage

from the battery:

Control, according to the diagram of

current path, if the cable does not
does not present short circuits between the
contact 2 of the sheet to 3 connections and the
positive terminal of the battery.

If no defects are detected on the cables:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

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Digifant ignition and injection system

Coolant temperature transmitter: control

Special tools, controllers and auxiliaries

necessary

V.A.G 1551 fault reader (or V.A.G 1552 vehicle system controller) with
07.93: V.A.G cable 1551/1
08.93: V.A.G cable 1551/3
◆V.A.G 1598/18 control unit
◆Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
◆V.A.G 1594 metrology adapter kit
Current flow diagram

Conduct of the control

Connect the V.A.G 1551 (V.A.G 1552) fault reader and select the control device
the engine electronics by entering "the address" 01. The engine should then idle.
V.A.G 1551 fault reader: connection and selection of the control device of the electronics
engine => page01-4.)

Display: Fast data transmission HELP

Choose the function XX

Enter code 08 corresponding to the

function "Read block of values from
"measure" and validate the entry by pressing
on the Q key.

Display: Basic Setting HELP

Enter display group number XX

Enter the code 01 corresponding to

"Display group number" and
validate the entry by pressing the
touch Q.

→Affichage: Read measurement value block 1 ⇒

(1 to 4 = display zones) 1 2 3 4

Read the temperature value of the

coolant.
Digifant 3.0 = display zone 1
Digifant 3.2 = display zone 2

Pursuit
Display Cause you
control
Cut or
=> page
-40°C short circuit
at the pole plus
24-50

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Short circuit => page

120°C
to the mass 24-52
only
if a defect
env.
sporadic
temperature
--- has been
the liquid
detected:2)
cooling
=> page
24-53

1) If a temperature is displayed that

differs greatly from the ambient temperature
from the transmitter, check if the cables of the
transmitters do not present any
pass-through resistors.

Control is only possible when

the engine is cold.

Continuation of the check if the display is -40

°C:

Unplug the two-plug connector -1-

of the temperature transmitter
coolant (G62) -2-.
Shunt the contacts of the sheet using
of
V.A.G auxiliary cables 1594 and
pay attention
à l'affichage.

Display 120 °C:

Replace the transmitter of

liquid temperature of
cooling -2-.

Display -40 °C:

Press the key⇒.

Enter the code 06 for "Finish the
data transmission" and validate
with the Q key.
Turn off the ignition.

→Connect the V.A.G control unit

1598/18 on the wiring of the device
order.
Control, based on the diagram of
current path, if the cable does not
does not have gaps between the
socket 14 of the control box and the
contact 1 of the sheet to 2 connectors.
Cable resistance: 1.5Ω max
Also check if the cable does not

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no short circuit at the pole

positive of the battery.
Assigned value: ∞ω

If no fault is detected on the cable:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

Continuation of the control if the display is 120

°C:

Unplug the 2-pin plug -1-

of the temperature transmitter of
coolant (G62) -2-.

-40 °C display:

Replace the transmitter of

liquid temperature of
cooling -2-.

Display 120 °C:

Press the key. ⇒

Enter the code 06 for 'Finish the
data transmission" and validate
with the Q key.
Turn off the ignition.
Unplug the device's plug from
order
Digifant.
Control, according to the scheme of
course of the current, between the plug of
the control device and contact 1
from the socket to 2 connectors, if the cable does not
no short circuits in the cable
of contact 2 as well as to the mass of
vehicle.
Assigned value: ∞ω

If no defect is detected on the cable:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

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Continuation of control if the temperature of

coolant is displayed:

Control of the transmitter operation

Observe the temperature value of

coolant.
Digifant 3.0 = display zone 1
Digifant 3.2 = display zone 2
The value of the temperature must
uniformly increase without
interruption.

Note:

If there are discrepancies of 2 to 5 °C at the level

values displayed by the reader of
flaws, it's the control device
who is at fault and not a transmitter
defective.
If there are operational anomalies of the
engine occurs
in certain temperature ranges
and that the value of
displayed temperature does not increase
without interruption, the
temperature signal is
momentarily cut off and the
Transmitter needs to be replaced.

Press the key ⇒.

Enter the code 06 to "Finish the
data transmission" and validate
with the Q key.

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Digifant ignition and injection system

Intake air temperature transmitter: control

Special tools, controllers, and auxiliaries

necessary

V.A.G 1551 fault reader (or V.A.G 1552 vehicle system controller) with
07.93: V.A.G cable 1551/1
08.93: V.A.G cable 1551/3
◆V.A.G control unit 1598/18
◆Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
◆V.A.G 1594 metrology adapter set
Current flow diagram
Refrigeration bomb (common in commerce)

Conduct of the control

With the ignition contact turned on, connect the V.A.G 1551 (V.A.G 1552) fault reader and select
the control device for the engine electronics by entering "the address" 01.
V.A.G 1551 fault reader: connection and selection of the control device for the electronics
of the engine => page01-4.)
When the control device for the engine electronics appears, note the version of the device.
of order.

→Display: Fast data transmission HELP

Choose the XX function

Enter the code 08 corresponding to the

function 'Read block of values from'
measure" and validate the entry by pressing
on the Q key.

→Display: Read measurement value block HELP

Enter display group number XX

Enter the 'Group Number'

display" and validate the entry in
pressing the Q key:
Digifant 3.0 = 03
Digifant 3.2 = 02

→Display: Read block of measurement values2 (3) ⇒

(1 to 4 = display zones) 1 2 3 4

Read the air temperature value

of admission.
Digifant 3.0 = display zone 3
Digifant 3.2 = display zone 4

Display Cause Pursuit

you

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control
Break or
=> page
-40°C short circuit at
24-55
plus pole
Short circuit at => page
120°C
the mass 24-57
env.
=> page
temperature. ---
24-58
ambient

1) If a temperature is displayed that

differs significantly from the ambient temperature
from the transmitter, check if the cables of the
transmitters do not present any
pass-through resistances.

Continued monitoring if the display is -40

°C:

Unplug the 2-pin connector -1-

the air temperature transmitter
admission (G42) -2-.
Shunt the contacts of the sheet using
of the
auxiliary cables of V.A.G 1594 and
pay attention
on display.

Display 120 °C:

Replace the transmitter of

intake air temperature -2-.

-40 °C display:

Press the key⇒.

Enter the code 06 to 'Finish the
data transmission and validate
with the Q key.
Turn off the ignition.

→Connect the V.A.G control unit

1598/18 on the wiring of the device of
order.
Control, based on the diagram of
current path, if the cable does not
does not have interruptions between the
socket 36 of the control box and the
contact 1 of the sheet to 2 connections.
Cable resistance: 1.5Ω max
Also check if the cable does not
no short circuit at the pole
positive of the battery.
Assigned value: ω∞

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If no defect is detected on the cable:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

Continuation of the control if the display is 120

°C:

Unplug the 2-terminal plug -1-

the air temperature transmitter
admission (G42) -2-.

Display -40 °C:

Replace the transmitter of

intake air temperature -2-.

Display 120 °C:

Press the key ⇒.

Enter the code 06 to "Finish the
data transmission" and validate
with the Q key.
Turn off the ignition.
Unplug the device's plug from
order
Digifant.
Check, at contact 1 of the connector to 2
connectors, if the cables going to the plug
of the control device does not
do not present a short circuit to the
contact 2 of the cable as well as towards the
vehicle mass.
Assigned value: ω∞

If no defect is detected on the cables:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

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Continuation of control if the temperature

ambient is displayed.

→ Place the transmitter of

intake air temperature (G42)
(the plug remains plugged in).
Note the air temperature value
of admission.
Digifant 3.0 = display zone 3
Digifant 3.2 = display zone 4
Vaporizer on the transmitter of the
aerosol refrigerant, current model,
while observing the value of the
temperature. The value of the
temperature must
decrease.
Press the key. ⇒
Enter code 06 to "Finish the
data transmission and validate
with the Q key.

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Digifant ignition and injection system

Engine speed transmitter: control

Special tools, controllers, and auxiliaries

necessary

◆V.A.G 1551 fault reader (or V.A.G 1552 vehicle systems controller) with
07.93: V.A.G cable 1551/1
08.93: V.A.G cable 1551/3
◆V.A.G control unit 1598/18
◆Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
◆V.A.G 1594 metrology adapter set
◆Current flow path diagram

Control condition

● After establishing the ignition contact, the starter should not yet have been activated.

Conduct of the control

With the ignition contact turned on, connect the V.A.G 1551 (V.A.G 1552) fault reader and select
the control device for the engine electronics by entering "the address" 01.
V.A.G 1551 fault reader: connection and selection of the control device for the electronics
of the engine => page01-4.)
When the control device for the engine electronics appears, note the version of the device
of order.

Display: Fast data transmission HELP

Choose the XX function

Enter the code 08 corresponding to the

function "Read block of values from
"measure" and validate the entry by pressing
on the Q key.

Display: Read measurement value block HELP

Enter display group number XX

Enter the "Group Number"

display" and confirm the entry in
pressing the Q key:
Digifant 3.0 = 01
Digifant 3.2 = 02

→Display: Read measurement value block 1 (2) ⇒

(1 to 4 = display zones) 1 2 3 4

Note the displayed injection duration.

Digifant 3.0 = display zone 4
Digifant 3.2 = display zone 2
Engage the starter. The indication of

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the injection duration must vary.

Note:

If the display on the fault reader is

interrupted when the starter is
activated, this is due to a tension of
functioning too weak for the reader of
defects during the launch. In this case, the
The vehicle's battery needs to be recharged.

Press the key ⇒.

Enter the code 06 for 'Finish the
data transmission" and validate
with the Q key.

If the indication of the injection duration does not change

pass

→Unplug the 3-pin connection

transmitter connections -1-.
Measure the voltage between the contacts
1+3 of the unplugged sheet.
Assigned value: 9 V minimum
Cut off the ignition contact.

→ Connect the V.A.G control box

1598/18 on the wiring of the device
order.
Control, based on the diagram of
current path, if the cables do not
do not have interruptions between the
control unit and the 3-pin connector
fittings.
Contact 1+socket 68
Contact 2+socket 67
Contact 3+socket 33
Cable resistance: 1.5Ω maximum
Also check if the cables do not
do not present a short circuit between
them.
Assigned value: ω∞

If no defect is detected in the cables

and if there was tension between contacts 1
+ 3:

Replace the speed transmitter.

engine (G28).

If no defect is detected in the cables

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and if there was no tension between the

contacts 1 + 3:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

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Digifant ignition and injection system

Idle switch: control

Control for the Digifant 3.0 (09.94)

(To inquire about the version of the control device => page01-4; V.A.G 1551 fault reader:
connection and selection of the control device for the engine electronics.)

Special tools, controllers, and auxiliaries

necessary

V.A.G control unit 1598/18

Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715

V.A.G Metrology Adapter Set

1594
◆Current flow diagram

Control process

Connect the V.A.G control unit

1598/18 on the device wiring
order.
Measure the resistance between the sockets
21 + 33.
Assigned value: 1.5ωmaxi
Open the butterfly. The resistance must
pass to
∞ ω.

If the assigned values are not reached:

Control, according to the diagram of

current path, if the cables do not
do not have interruptions between the
control box and the 2-pin connector
fittings.
Contact 1+socket 21
Contact 2+douille 33
Cable resistance: 1.5Ω max

Control for the Digifant 3.2 (10.94)

(To query the device version of

command => page01-4; Defect reader
V.A.G 1551: connection and selection of
the control device for the electronics of the
engine.)

Special tools, controllers, and auxiliaries

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necessary

◆V.A.G 1551 fault reader or

vehicle systems controller
V.A.G 1552 with cable V.A.G 1551/3
V.A.G control unit 1598/18
Portable multimeter V.A.G 1526 or
multimeter
V.A.G 1715
◆V.A.G metrology adapter set
1594
◆Current flow diagram

Conduct of the control

Connect the V.A.G fault reader

1551 (V.A.G 1552) and select
the control device of
motor electronics upon entering
the address 01. The engine must then
slow motion.
V.A.G 1551 Fault Reader:
connection and selection of the device
of electronic motor control
=> page01-4.)

→Display: Fast data transmission HELP

Choose the function XX

Enter the code 08 corresponding to the

function 'Read block of values from'
measure" and validate the input by pressing
on the Q key.

→Display: Read measurement value block HELP

Enter display group number XX

Enter code 01 corresponding to

Display group number
validate the entry by pressing the
touch Q.

Display: Read measurement value block 1 ⇒

(1 to 4 = display areas) 1 2 3 4

Take into account the number in the 4th position

from the left in the area
display 4 of the 8-digit block.
Assigned value: 00000000
Gently open the butterfly.
The display in 4th position must skip.
on 1.
Display: 00010100

If the assigned values are not met:

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Pursuit
Display Cause you
control
Short circuit to => page
still 0
the mass 24-65
Cut or
=> page
always 1 short circuit at
24-66
pole plus

Continuation of the check if the display is

always 0:

Unplug the 2-prong plug -1-

of the idle switch (F60) -2-.

Display 1:

Replace the idle switch -2-.

Display 0:

Press the key . ⇒

Enter code 06 to "Finish the
data transmission and validate
with the Q key.
Cut off the ignition contact.
Unplug the device's plug from
order
Digifant.
Check at contact 1 of the connector to 2
connections if the cables going to the plug
of the control device does not
do not present short circuits at
contact cable 2 as well as to ground.

If no defects are detected on the cable:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

Continuation of control if the display is

always 1:

→Unplug the 2-pin plug -1-

of the idle switch (F60) -2-.
Shunt the contacts of the sheet using
of the
Auxiliary cables of V.A.G 1594 and
pay attention
on display.

Display 0:

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Replace the idle switch -2-.

Display 1:

Press the key. ⇒

Enter the code 06 to "Finish the

data transmission" and validate
with the Q key.
Turn off the ignition.
Connect the V.A.G control unit
1598/18 on the wiring of the device of
order.

Control, according to the scheme of

path of the current, if the cables do not
do not have breaks between the
control box and the 2-pin connector
fittings.
Contact 1+socket 21
Contact 2+socket 33
Cable resistance: 1.5Ω max

If no defects are detected on the cables:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

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Digifant ignition and injection system

Idle switch: replacement and adjustment

Idle switch: replacement

Special tools, controllers, and auxiliaries

necessary

Caliper or depth gauge

Work process

Remove the throttle nozzle.

→Measure the gap between the butterfly and the
sealing surface -a- and note it.
Replace the idle switch
(F60) -1-.
Adjust the butterfly by moving it
idle switch -1-
in such a way that the rating -a- is
new
reached.

Note:

The throttle adjustment must be made with

one

particular precaution. The rating -a- must not in

none

may be surpassed.

Idle switch: adjustment

Special tools, controllers and auxiliaries

necessary

◆Vernier caliper or gauge of

depth

Work process

→Loosen the idle switch -1-.

Slowly close the butterfly (the stop
from the meat
sectorial should not rely on
the switch
of slow motion).
Measure the gap between the butterfly and the
sealing surface -a- and note it.

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Adjust the butterfly by moving it

contactor of
slow down -1-.
Adjustment dimension a = dimension noted a +
0.5 mm

Note:

The throttle adjustment must be made with

a

particular precaution. The setting rating -a-

no

must not be exceeded under any circumstances.

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Digifant ignition and injection system

Power supply of the control device: control

Special tools, controllers, and auxiliaries

necessary

◆V.A.G 1551 fault reader (or V.A.G 1552 vehicle systems controller) with
07.93: V.A.G cable 1551/1
08.93: V.A.G cable 1551/3
◆V.A.G control unit 1598/18
◆Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
◆V.A.G 1594 metrology adapter set
Current flow diagram

Control conditions

● Battery voltage 11 V minimum

● Alternator in good condition

Conduct of the control

With the ignition turned on, connect the V.A.G 1551 (V.A.G 1552) fault reader and select
the control device for the engine electronics by entering 'the address' 01.
(V.A.G 1551 Fault Reader: connection and selection of the control device for the electronics
of the engine => page01-4.)
When the control device for the engine electronics appears, note the version of the device.
of order.

→Display: Fast data transmission HELP

Choose the function XX

Enter the code 08 corresponding to the

function 'Read block of values from
"measure" and validate the entry by pressing
on the Q key.

Display: Read measurement value block HELP

Enter display group number XX

Enter the "Group Number"

of display" and validate the entry in
pressing the Q key:
Digifant 3.0 = 03
Digifant 3.2 = 02

→Display: Read block of measurement values2 (3) ⇒

(1 to 4 = display zones) 1 2 3 4

Read the voltage value.

Digifant 3.0 = display zone 4
Digifant 3.2 = display zone 3

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Assigned value: approx. voltage of the

battery (constant value)
Press the key ⇒.
Enter the code 06 to "Finish the
data transmission and validate
with the Q key.

If the displayed value is fluctuating or if the

battery voltage is not reached:

Turn off the ignition.

→Connect the V.A.G control unit

1598/18 on the device wiring of
order.
Turn on the ignition.
Measure the supply voltage between
the sockets 1+23 of the control box
with the multimeter and the cables
V.A.G auxiliaries 1594.
Assigned value: 11 V minimum
Measure the tension between the sockets
1+9 from the control box using the
multimeter and auxiliary cables of
V.A.G 1594.
Assigned value: 9 V minimum

If the assigned values are not reached:

Replace the power relay

tension (J176).

Power supply for terminal 15:

control

Measure the supply voltage between

the sockets 1+38 of the control box
with the multimeter and cables
V.A.G auxiliaries 1594.
Assigned value: 11 V mini

If the assigned value is not reached:

Check the cable connections in

function of the route diagram of
current.

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Digifant ignition and injection system

Control device for engine electronics: adaptation to
the electronic immobilizer

only on vehicles 10.94

Special tools, controllers and auxiliaries

necessary

V.A.G 1551 fault reader or V.A.G 1552 vehicle system controller with V.A.G 1551/3 cable

Condition to be fulfilled

The key belonging to the vehicle and recorded as 'authorized' in the control device.
the electronic immobilizer must be available.

Work process

Put down the ashtray and push it.

diagnostic socket cover towards the
left arrow
Connect the fault reader (or the
vehicle systems controller
the help of the V.A.G 1551/3 cable.
Turn on the ignition.
Use the fault reader while holding
count of displayed instructions:
Enter code 1 for "Transmission"
fast data
Enter the code 25 corresponding to
the "Immobilizer" address and validate
with the Q key.
When the device identification of
command for the immobilizer is
displayed, press the key ⇒.

→Display: Fast data transmission HELP

Choose function XX

Enter the code 10 for the function

Adaptation and validate with the key
Q.

Display: Adaptation
Enter the channel number XX

Enter the code 00 for the number of

channel 0 and validate with the Q key.

Display: Adaptation Q

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Remove the self-adaptive values?

Validate by pressing the Q key.

→Display: Adaptation ⇒
The self-adaptive values are erased.

Complete the adaptation by pressing

the key
Enter code 06 to 'Finish the
data transmission" and validate
with the Q key.
Turn off the ignition.

Note:

When the next contact is made

from ignition, the device code of
The engine command is stored in memory.
in the control device of
the anti-theft system.

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Digifant ignition and injection system

Starter signal: check

Special tools, controllers, and auxiliaries

necessary

V.A.G 1598/18 control unit

Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
◆ V.A.G 1594 metrology adapter set
◆Current flow diagram

Conduct of the control

Connect the V.A.G control unit

1598/18 on the wiring of the device
order.
To measure the voltage, connect the
multimeter with 1+7 sockets from the case
of control.
Engage the starter. A value of
8 V mini
must be displayed on the multimeter.

If the assigned value is not reached:

Control, based on the diagram of

current pathway, the connection by
cable going to terminal 50 of
starter.

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Digifant ignition and injection system

Injectors: control

Activation: control

Special tools, controllers, and auxiliaries

necessary

V.A.G 1598/18 Control Unit

Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
V.A.G 1527 LED indicator lamp
V.A.G 1594 Metrology Adapter Set
◆Current flow diagram

Control conditions

Engine speed transmitter in good condition

Fuel pump relay in good condition

state

Conduct of the control

Unplug the plug -1- from the connection -

2- and
connect the LED indicator light
V.A.G 1527 with
the auxiliary cables of V.A.G 1594 on
the contacts 1 + 5
of the sheet.
Activate the starter.
The light-emitting diode must
to blink
Repeat the check on contacts 2 + 5,
3 + 5 and
4 + 5.

If the light-emitting diode does not flicker:

Turn off the ignition.

→ Connect the V.A.G control unit

1598/18 on the wiring of the device
order.
Control, based on the scheme of
current circuit, if the cables do not
do not have interruptions between the
control box and the connection to
sheet with 5 connectors.
Contact 1+socket 24

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Contact 2+socket 25
Contact 3+socket 26
Contact 4+socket 2
Cable resistance: 1.5Ω max
Control, according to the diagram of
current path, if the cable does not
no interruptions between the
contact 5 from connection to file at 5
fittings and the relay mounting plate.
Cable resistance: 1.5Ω max
Also check if the cables do not...
do not present a short circuit between
them.
Assigned value: ∞ω

Resistance of injectors and cables:

control

Check the resistance of all the

injectors with contacts
the connection -2-.

Injector 1 2 3 4
Contacts 1+5 2+5 3+5 4+5

Assigned value: 15 to 20Ω

If the assigned value is not reached:

Place the upper part of

intake manifold.

Attention
The power supply system is under
pressure. Before loosening some
flexible connections or to open it
control fitting, surrounded by a
Chiffon the connection point. Reduce
then the pressure by unplugging
carefully the hose or, as the case may be,
the sealing cap.

Remove the fuel distributor, the

disassemble and repeat the control over
the different injectors; if necessary,
replace the injector(s).

Jet shape and sealing: control

Special tools, controllers, and auxiliaries

necessary

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Digifant ignition and injection system

Fuel pressure regulator and retention pressure: control

Special tools, controllers and auxiliaries

necessary

Pressure measuring device V.A.G 1318

Adapter 1318/10

Control condition

Fuel pump flow is correct, check:

=> Response group 20; Fuel system components: removal and installation; Fuel pump: check

Procedure of the control

Attention
The supply system is under pressure. Before disconnecting the sealing cap, surround
from a cloth the connection point. Then reduce the pressure by carefully unplugging the cap.
of obstruction.

Unplug the sealing cap

-1- the measuring connector -2-. For this
do, unlock the cap
of obstruction by compressing it
laterally -arrows-.
Connect the manometric device
V.A.G 1318 with the adapter 1318/10
at the measuring connection.

Attention
The stopcock of the device
the manometer must be closed (lever
perpendicular to the flow direction -arrow-
).

Start the engine and make it run at

slow down.
Measure the fuel pressure.
Assigned value: ambient pressure 2.5
bar

Disconnect the vacuum hose

-1- of the nozzle
de raccord -2-.
The fuel pressure must
increase to
env. 3.0 bar.
Turn off the ignition.

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Check the seal and pressure of

withholding while observing the fall of
pressure on the manometer. After
10 minutes, we still have to observe
a minimum pressure of 2 bar.

If the holding pressure drops below

of 2 bar:

Start the engine and run it at

slow down.
After establishing the pressure,
cut off contact
of ignition. At the same time, pinch from
watertight way
flexible of the return driving - with
blue arrow - on
the fuel distributor.
Observe the drop in pressure on the
manometer.

If the pressure does not drop:

Replace the pressure regulator of the

fuel.

If the pressure drops again:

Check the check valve of the

fuel pump.

=> Group of reply 20; Parts of the system

food supply: removal and reinstallation; Pump to
carburant: contrôle

Check the tightness of the connections of

pipes, O-rings of the
fuel distributor and
injectors.

Note:

Before removing the pressure gauge device,

lower the fuel pressure by opening
the shut-off valve. Hold a container in front
the opening throughout the operation.

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Digifant ignition and injection system

Admission system: sealing control (secondary air intake)

Special tools, controllers, and auxiliaries

necessary

Ignition controller V.A.G 1767 or V.A.G 1367 with

V.A.G impulse pliers 1367/8
CO Analyzer V.A.G 1363 A or
4 gas analyzer V.A.G1788
◆V.A.G 1363/3 Adapter
◆Leak location bomb G 001 800 A1

Control process

Note:

Due to the prevailing depression in the system

upon admission, the leak localization product is
sucked in with the parasitic air. The localization product
Leaks reduce the flammability of the mixture, which
leads to a decrease in engine speed and a strong
increase in CO content.
◆The safety instructions mentioned on the bomb
must be strictly observed.

→Plug in the ignition controller

V.A.G 1767
or the ignition controller V.A.G 1367
help
from the impulse pliers V.A.G1367/8.

With the help of the V.A.G1363/3 adapter,

connect the V.A.G CO analyzer
1363A or the V.A.G 1788 gas analyzer
on CO measurement tube.
Start the engine and let it run at
slow down.
Systematically vaporize the product

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of localization of leaks the parts of

admission system.

If the engine speed decreases and if the content in

How does it vary?

Check the sealing of the points of

admission system on which the
the product has been sprayed and eliminated
leaks.

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Digifant ignition and injection system

Intake air heating: control

Special tools, controllers and auxiliaries

necessary

Hand vacuum pump V.A.G 1390

Control condition

Sealed regulation flap depression capsule

Regulation flap: control

Remove the upper body of the air filter and take out the filter cartridge.
Connect the V.A.G 1390 hand vacuum pump to the vacuum line going to the capsule.
depression.

Activate the pump and control it

mobility of the regulation flap and the
correct functioning of the capsule
of depression.
The regulating shutter must close the
fresh air connector -1-.

Temperature regulator: control

Set up the upper body of the

air filter so that the flap of
regulation should be visible in the body
lower part of the air filter.
Connect the vacuum lines
on the temperature regulator.
Connect the transmitter of
intake air temperature.
Start the engine and make it run at
slow down.

→Control the position of the shutter

regulation after 20 seconds
maxi.

Temperature of Position of
regulator of shutter of
temperature regulation
air connector
less than 20°C
costs -1- obscured
air connection
more than 30°C warm -2-
obturated

between connection

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fresh air and

between 20 and 30 °
air connector
C
hot

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Digifant ignition and injection system

Ignition part: restoration

Note:

This chapter only deals with components directly related to ignition. For the others
ignition and injection system components => repair group 24.
◆The control device of the ignition and injection system is equipped with a self-diagnosis.
◆The components marked with the * symbol are monitored by self-diagnosis.
◆Before carrying out repairs and for troubleshooting, check the fault memory.
=> page01-6, Memory of defects: questioning and
erasure

Security measures => page 28-7

Control characteristics, spark plugs => page 28-8

Spark plug, 30
Nm
Drop and replace
with 3122B.
Type and spacing
electrodes
=> page28-8
2. Ignition cable
◆Control the
continuity
electric
3. Candle sheet
ignition
4 to 6 kΩ
Only remove with
the ring
extraction -4-
4. Extraction ring
O-ring
Replace in case
of damage
6. Lighter with
transmitter of
cylinder 1 detection
(G145) * or transmitter
de Hall (G40)*
Disassemble and
assembler
=> page28-5
◆Control the
transmitter of
Hall or the
transmitter of
detection of
cylinder 1 => page
28-10

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Ignition rotor:
replace
page28-18,
marker: R1,
resistance: 0.6 to
1.4 kΩ

7.10 Nm
8. Cylinder marker
1
Hood
dust cover
10. Card
anti-parasitic
◆ 0.6 to 1.4
kω
11. Card of
connection
12th floor for
transformer
of ignition
(N157)
◆Control
=> page
28-11
◆ Only
the version
screwed may
to be
replaced
separately
13. 10 Nm
Transformer
of ignition
(N152)
◆ Control
=> page
28-11
Mass braid
16. Hat of
armoring

Distributor cap
To do
beware of
fissures and
to the traces
of currents
of leak
Control

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the wear of
contacts
Clean
before the
putting in
place
◆ Check
usury and the
good
mobility of
coal
18. Connection to file
3 connections
◆For
detector of
clicks 1:
brown
◆ For
detector of
clicks 2:
black
Contacts
gilded
On the
support of the
connection to
card
central
cylinder head at
left
19. Detector of
cliquetis 2 (G66)*
In the direction
from the
market, to
left
20. 20 Nm
The couple of
tightening to
a
influence on
the
functioning
of the detector
of clicking
21. Detector of
clicks 1 (G61)*
In the direction
of the
market, at
right

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Système d'allumage et d'injection Digifant

Lighter: disassembly and assembly

Note:

During the assembly,

ensure that
the mating -7- be
slightly mobile on the
pin -8- and to what
the game in relation to
the tree of the lighter -1- does not
don't be limited.

Ignition Coil
With screen
of the rotor and
rotor
of the lighter
Extract it
after
deposit of
the pin
of tightening
-7-.
2. Round(s) of
compensation
3. Round piece in
plastic
4.3 Nm
5. Transmitter of
detection of
cylinder 1 (G145)
or transmitter
de Hall (G40)
Control
=> page
October 28

Ignition box
7. Coupling
◆ Before the
deposit
spot it
position of
dowel
training
in relation to
the tree -1- .
8. Pin
9. Safety spring

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Digifant ignition and injection system

Security measures
To avoid all bodily harm and/or destruction
of the ignition and injection system, take this into account
who follows:

◆Do not touch or unplug the ignition cables when

the engine is running or is at its starting speed.
◆Do not disconnect and reconnect the system cables
of ignition and injection - including the cables of the devices
of measurement - only when the ignition switch is turned off.
If the engine is to run at launch speed without
to be launched, e.g. for monitoring the compression rate,
disconnect the plug connection of the transmitter from
regime (on the support of the cylinder head, at the bottom
to the left).
◆Do not connect a capacitor to terminal 1 (-).
◆Do not replace the distributor rotor 1 kΩ (marker: R1)
by another model, even in case of anti-parasiting of
the car radio.
◆ For anti-parasitic purposes, use only for cables
high tension, 1 kΩ resistors and plugs of
spark plugs of 5 kΩ.

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Digifant ignition and injection system

Control characteristics, spark plugs

Reference letters engine ABF

Ignition Point 1)
control => page24-24, basic settings
Ignition order 1-3-4-2
Spark plugs
VW/Audi 101 000 035 AE 101 000 016 AA
Manufacturer designation NGK BK 7 EKU Bosch F5 DPO R
Spacing of the electrodes
Electrode spacing 0.8 mm4)maxi 0.6...0.7 mm
Torque couple 30 Nm 30 Nm

Non-adjustable

2) Updated values and replacement frequency of spark plugs:

Pollution Control Service Folder

3) Deposit and restore with 3122B

Distance between ground electrodes and ceramic insulator of the spark plug

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Digifant ignition and injection system

Advance on ignition: control

Special tools, controllers and auxiliaries

necessary

Ignition controller V.A.G 1767 or V.A.G 1367 with

V.A.G 1367/8 impulse pliers

Control conditions

Absence of defects in the defect memory

●Engine oil temperature: 80°C min

Conduct of the control

Connect the ignition controller

V.A.G 1767
or the V.A.G 1367 ignition controller
help
from the impulse pliers V.A.G1367/8.
Start the engine and let it run at
slow down.
Set the ignition controller to
3500/min.
Gradually increase the regime to a
a little more than
3500/min, until the point
of ignition (value
(ahead) should be displayed.
Assigned value: 32 to 36° before
PMH

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Digifant ignition and injection system

Cylinder 1 detection transmitter/Hall transmitter: control

Special tools, controllers, and auxiliaries

necessary

Control unit V.A.G 1598/18

Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
◆ V.A.G 1594 metrology adapter set
◆Current flow diagram

Control condition

Fault detected on the transmitter by self-diagnosis

Process of the control

Unplug the transmitter plug

(lighter).
For measuring the voltage,
connect the multimeter to the contacts
exteriors of the card using the
V.A.G auxiliary cables 1594.
Put the ignition contact.
Assigned value: 10 V min
Turn off the ignition.

Connect the V.A.G control unit.

1598/18 on the wiring of the device
order.
Control, according to the scheme of
current path, if the cables do not
do not have interruptions between the
control box and the 3-pin plug
fittings.
Contact 1+socket 33
Contact 2+socket 44
Contact 3+socket 45
Cable resistance: 1.5Ω max
Also check if the cables do not
do not present a short circuit between
them.

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Assigned value: ω∞

If no defects are detected in the cables

and if there was tension between the contacts 1
+ 3:

Replace the transmitter => page28-

5.

If no defects are detected in the cables

and if there were no tension between the
contacts 1 + 3:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

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Digifant ignition and injection system

Cylinder 1 detection transmitter/Hall transmitter: control

Special tools, controllers, and auxiliaries

necessary

V.A.G 1598/18 control unit

Handheld Multimeter V.A.G 1526 or multimeter
V.A.G 1715
◆ V.A.G 1594 metrology adapter set
◆Current flow diagram

Control condition

Fault detected on the transmitter by self-diagnosis

Conduct of the control

Unplug the transmitter plug

(lighter).
For measuring the voltage,
connect the multimeter to the terminals
exteriors of the sheet using the
V.A.G auxiliary cables 1594.
Turn on the ignition.
Assigned value: 10 V min
Turn off the ignition.

Connect the V.A.G control unit

1598/18 on the wiring of the device
order.
Control, according to the scheme of
course of the current, if the cables do not
do not have interruptions between the
control box and the 3-pin plug
fittings.
Contact 1+socket 33
Contact 2+socket 44
Contact 3+socket 45
Cable resistance: 1.5Ω max
Also check if the cables do not
do not present a short circuit between
them.

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Assigned value: ω∞

If no defects are detected in the cables

and if there was tension between contacts 1
+ 3:

Replace the transmitter => page 28-

5.

If no defect is detected in the cables

and if there were no tension between the
contacts 1 + 3:

Replace the control device

Digifant (J169)
=> page24-8, position -11-.

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Digifant ignition and injection system

Ignition transformer: control

Special tools, controllers, and auxiliaries

necessary

Portable multimeter V.A.G 1526 or multimeter

V.A.G 1715
V.A.G 1594 Metrology Adapter Set

Conduct of the control

Unplug the connection plug and the ignition cable from the ignition transformer (N152).

→Check the primary resistance with

the portable multimeter V.A.G 1526 enters
the terminals 1 and 15.
Assigned value: 0.5 to 1.2Ω
Check the secondary resistance with
the handheld multimeter between terminals 4
and 15.
Assigned value: 3 to 4 kΩ

If the assigned values are not met:

Replace the transformer

of ignition.

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Digifant ignition and injection system

Final stage of the ignition transformer: control

Special tools, controllers and auxiliaries

necessary

V.A.G control unit 1598/18

Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
◆ V.A.G 1527 LED indicator light
◆V.A.G 1594 metrology adapter set
◆Current path diagram

Conditions of control

Hall sensor or cylinder detection sensor 1 in good condition

Engine speed transmitter in good condition
● Ignition transformer in good condition

Voltage supply: control

Unplug the 3-pin connector from the ignition transformer.

For measuring the voltage,

connect the multimeter to contacts 1
and 3 of the sheet
disconnected using cables
auxiliaries of
V.A.G 1594.
Mettre le contact d'allumage.
Assigned value: 11 V minimum

In the absence of tension:

Cut off the ignition contact.

Control, based on the diagram of
current path, if the cable does not
does not have interruptions between the
contact 1 of the sheet to 3 connections and the
mass.
Cable resistance: 1.5Ω max
Control, according to the diagram of
current path, if the cable does not
does not have cuts between the
contact 3 of the sheet to 3 connectors and the
relay plate.
Cable resistance: 1.5Ω max

Activation: control

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Unplug the 5-pin connector

connections going to the injectors -arrow-.

→Connect the LED indicator lamp

V.A.G 1527 aux
contacts 2 and 3 of the sheet using the
cables
V.A.G 1594 auxiliaries and
adapters
V.A.G 1594/15.
Activate the starter and control it
ignition signal coming from the device
of the Digifant order.
The light-emitting diode must
to sway

If the light-emitting diode does not flicker:

Connect the V.A.G control box

1598/18 on the wiring of the device
command.
Control, according to the schema of
current path, if the cable does not
does not show any interruptions between the
socket 8 of the control box and the
contact 2 of the sheet to 3 connections.
Cable resistance: 1.5Ω max
Also check if the cables are not
do not present a short circuit between
them.
Assigned value: ∞ω

If no defects are detected in the cables

and if there was tension between contacts 1
+ 3:

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Replace the control device

Digifant (J169)
=> page24-8, position -11-.

If the power supply and activation are

corrections

Connect the plug to 3 connectors and the

ignition cable on the transformer
of ignition.
Connect the LED indicator lamp
to contacts 1 and 15 of the transformer
of ignition, using the cables
auxiliaries and boundaries.

Attention
During the following check, do not touch either
the connections of the transformer
neither the ignition nor the control cables.

Turn on the ignition.

The light-emitting diode must
light up
for 1 to 2 seconds.
Activate the starter.
Light Emitting Diodes
must waver;
if necessary, replace the final floor.

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Digifant ignition and injection system

Knock detectors: control

Special tools, controllers, and auxiliaries

necessary

Control unit V.A.G 1598/18

Portable multimeter V.A.G 1526 or multimeter
V.A.G 1715
◆ V.A.G 1594 Metrology Adapter Set
◆Current flow diagram

Control condition

Defect detected by self-diagnosis on one or both knock detectors

●Fault memory erased

Conduct of the control

→Disconnect the 3-pin plug connection

brown fittings going to the detector of
clicks 1 (G61) -1- or the connection to
black 3-socket connector going to
knock detector 2 (G66) -2-.
Measure the resistance between the
contacts 1+2, 1+3 and 2+3 at the junction of
knock detector.
Assigned value: ∞ω

Connect the V.A.G control unit

1598/18 on the wiring of the device
order.
Control, according to the diagram of
current path, if the cables do not
do not have breaks between the
control box and the 3-pin connector
fittings.
G61: G66:
Contact 1+socket 34 57
Contact 2+socket 32 56
Contact 3+socket 10 55
Cable resistance: 1.5Ω max
Also check if the cables do not

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do not present a short circuit between them.

Assigned value: ∞ω

If no defects are detected on the cables:

Loosen the knock sensor and the

tighten to 20 Nm.

If the complaint still exists (default of

new in the defect memory):

Replace the detonation detector.

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Digifant ignition and injection system

Distributor rotor: replacement

Special tools, controllers, and auxiliaries

necessary

Sealing liquid AMV 185 100 01

The distributor rotor is stuck on the shaft. If the rotor

must be replaced, the old rotor needs to be destroyed,
what can be achieved e.g. by crushing it using
of a clamp.

Note:

Do not break the rotor with a hammer, as this may damage the ignition shaft or the bearings.

Carefully remove the remaining debris from the tree.

on the tree and stick the new rotor with
AMV 185 100 01.

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