Motronic ignition system, servicing Page 1 of 25

28-2

Motronic
ignition
system,
servicing
Note:

Motronic Engine
Control Module
(ECM) J220* with
connector
page 24-9 , item
16 .

1 - High-
voltage
ignition
cable
Ignition
secondary
circuit
Check
for
continuity
2 - Suppressor
Resistance:
0.6-1.4 k
3 - Ignition
coil
terminal 1
4 - Ignition
coil
terminal
15
5 - Ignition
coil power
output
stage -
N157-*

Checking

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page
28-20
6 - 10 Nm (7 ft
lb)
7 - Ignition
coil -N152-
Checking
page
28-19

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28-3

8 - Harness
connector
3-pin
9 - Ground
(GND)
strap
10 - Knock
Sensor
(KS) 1 -
G61-*
11 - 20 Nm (15
ft lb)
Tightening
torque
influences
knock
sensor
function
12 - Spark plug
connector
Use
3277
when
pulling
off and
pushing
on
Resistance:
4-6 k
13 - Spark plug
Tightening
torque: 30
Nm (22 ft
lb)
Remove
and
install
with
3122B

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Spark
plug type
and
electrode
gap
page 28-
7
14 - 25 Nm (18
ft lb)
15 - Clamp

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28-4

16 - O-ring
Replace
if
damaged
17 - Distributor
with
Camshaft
Position
(CMP)
sensor -
G40-*
Installing
page
28-8
Checking
CMP
sensor
page 28-
15
18 - Dust cap
19 - Rotor arm
Marking:
R1
Resistance:
0.6-1.4 k
20 - Distributor
cap
Check
for
cracks
and
signs of
tracking
Check
contact
wear
Clean
before
fitting

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Check
carbon
brush for
wear and
freedom
of
movement
21 - Shielding
cap

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28-5

Safety precautions

WARNING!

Be alert when working on or near the engine.

High ignition secondary voltage can cause
serious personal injury and damage vehicle
components.

DO NOT touch or disconnect ignition system

wires when the engine is running or being
cranked at starting RPM.

DO NOT operate the starter if the fuel

injectors have been removed.

Be sure the ignition is switched OFF, when:

Disconnecting ignition wires

Disconnecting fuel injection system wiring

Connecting or disconnecting test equipment

leads

Disconnecting the battery

Washing the engine or engine

compartment.

BEFORE cranking the engine at starting RPM

(such as for compression testing) disable the
ignition and fuel injection systems:

Disconnect the ignition coil power output

stage.

Disconnect harness connectors from all fuel

injectors.

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After the work is completed, erase

Diagnostic Trouble Code (DTC) memory.

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28-6

CAUTION!

BEFORE disconnecting the battery:

Stop the engine.

Be sure the ignition is switched OFF (also

applies when connecting the battery). Failure
to do so may damage the Engine Control
Module (ECM).

Be sure of the proper radio code (for vehicles

equipped with coded anti-theft radio).

Be sure the battery negative (-) cable is

disconnected, when:

Working on the electrical system

Resistance (spot) welding or electric arc

welding anywhere on the vehicle.

When connecting and disconnecting

electrical test equipment (LED voltage tester,
multimeter, etc.):

Be sure the ignition is switched OFF.

Use correct adapters from the VW 1594

connector test kit.

For any work affecting the Engine Control

Module (ECM):

BEFORE disconnecting the ECM harness

connector, switch the ignition OFF and WAIT
at least 20 seconds. Failure to do so may
damage the ECM.

DO NOT connect any outside voltage source

to stimulate an output signal at the ECM.

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28-7

Technical data, spark plugs

Engine code ABA

Ignition timing1)
Checking page 24-23
Firing order 1-3-4-2
Spark plugs1)
VW/Audi 101 000 044
AA
Manufacturer's FR 8 DS
designation
Electrode gap 2) 0.8 mm

(0.031 in.)
Tightening torque 30 Nm

(22 ft lb)

1) Not adjustable

2)Gap between ground electrodes and center

electrode insulation

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28-8

Distributor, removing and

installing

Special tools, testers and auxiliary

items

Pin wrench Matra V159

Torque wrench VAG 1331 (5-50

Nm)

Note:

The Motronic Engine Control Module

(ECM) requires the Cyl. 1 TDC signal
from the camshaft position sensor in the
distributor in order to allocate the fuel
injection and knock sensor systems
according to the firing order.

Checking Cyl.1 Top Dead Center

(TDC) markings

- Set flywheel -A- or automatic

transmission drive plate -B- to align
marks for Cyl.1 TDC.

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28-9

Engine removed

Set vibration damper (V-belt pulley) to

mark for Cyl.1 TDC.

Mark on camshaft sprocket must

align with arrow on cylinder head
cover.

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28-10

Mark on distributor housing must

align with mark on rotor arm or
camshaft position sensor cover.

Removing

Crankshaft and camshaft in Cyl.1

TDC position
- Remove distributor.

Installing

- Align oil pump shaft drive lug parallel

to crankshaft.

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28-11

- Install distributor.
Pins on distributor must point
toward mounting bolt threaded hole
(arrow).

Note:

When installing, turn the rotor arm

slightly the the right of the distributor
marking (clockwise). When inserting the
distributor and meshing the drive gears,
the rotor arm will turn back toward the
marking.

Mark on distributor housing must

align with mark on rotor arm or
camshaft position sensor cover.
- Tighten distributor securing bolt.
Tightening torque: 25 Nm (18 ft lb)

If the markings cannot be aligned

correctly:

- Loosen toothed drive belt tensioner

roller and remove toothed belt from
camshaft sprocket.

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28-12

- Turn intermediate shaft sprocket with

toothed drive belt (in direction of
arrows) until rotor arm aligns with
markings for Cyl.1 on distributor
housing.
(Toothed belt slides over crankshaft
sprocket.)

Mark on distributor housing must

align with mark on rotor arm or
camshaft position sensor cover.
- Position toothed drive belt onto
tensioner roller and camshaft
sprocket.

Note:

For easier installation of the toothed

belt, loosen the tensioner roller lock nut
by only approx. one thread.

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28-13

- Turn tensioner with pin wrench (e.g.

Matra V159) in direction of arrow to
adjust toothed drive belt tension.
It must be just possible to turn the
toothed belt through 90 with the
thumb and forefinger in the center
between camshaft and intermediate
shaft sprockets.
- Tighten tensioner lock nut.
Tightening torque: 45 Nm (33 ft lb)
- Rotate crankshaft two full turns and
check adjustment.
- Check distributor housing and rotor
arm markings.
- Install upper toothed drive belt cover.
- Before installing, clean distributor
cap, check for cracks and signs of
tracking, and replace if necessary.

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28-14

Ignition timing control, checking

Special tools, testers and auxiliary

items

VAG 1767 ignition tester, or VAG

1367 ignition tester with VAG
1367/8 HT pick-up clamp

Check conditions

Engine oil temperature at least 80

C (176 F)

Test sequence

- Connect VAG 1767 ignition tester, or

VAG 1367 ignition tester with VAG
1367/8 HT pick-up clamp.
- Start engine and run at idle speed.
- Set ignition tester to 3000 RPM.
- Slowly increase engine speed to
slightly above 3000 RPM until the
ignition timing (advance figure) is
indicated.
Specification: 29 -34 before TDC

If the specification is not attained:

- Replace Motronic Engine Control

Module (ECM) J220 page 24-9 ,
item 16 .

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28-15

Camshaft Position (CMP) sensor,

checking

Special tools, testers and auxiliary items

VAG 1598/18 test box

Multimeter (Fluke 83 or equivalent)

VW 1594 connector test kit

Wiring diagram

Test sequence

- Disconnect harness connector from sensor

(distributor).

- Connect multimeter to measure voltage at outer

connector terminals using adapter cables from
VW 1594.
- Switch ignition on.
Specification: min. 4.5 volts
- Switch ignition off.

If the specification is not attained:

- Connect VAG 1598/18 test box to ECM wiring

harness.

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28-16

- Check wiring for open circuits

between test box and 3-pin
connector, according to wiring
diagram.
Terminal 1 and test box socket
56
Terminal 2 and test box socket
44
Terminal 3 and test box socket
41
Wire resistance: Max. 1.5
- Additionally check wires for short
circuits to one another.
Terminal 3 and test box socket
44
Terminal 3 and test box socket
56
Terminal 2 and test box socket
56
Specification: (no continuity)

If no wiring malfunction is detected and

voltage was present between terminals
1 and 3:

- Replace distributor with CMP sensor

page 28-4 , item 17 .

If no wiring malfunction is detected and

no voltage was present between
terminals 1 and 3:

- Replace Motronic Engine Control

Module (ECM) J220 page 24-9 ,
item 16 .

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28-17

Knock sensor, checking

Special tools, testers and auxiliary

items

VAG 1598/18 test box

Multimeter (Fluke 83 or equivalent)

VW 1594 connector test kit

Wiring diagram

Test sequence

- Disconnect brown 3-pin harness

connector -2- from knock sensor 1
G61 socket -1-.
- Measure resistance between
terminals 1 and 2, 1 and 3 and 2 and
3 at knock sensor connector socket.
Specification: (no continuity)

If the specification is attained:

- Connect VAG 1598/18 test box to

ECM wiring harness.

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28-18

- Check wiring between test box and

3-pin connector for open circuit
according to wiring diagram.
Terminal 1 and test box socket
34
Terminal 2 and test box socket
33
Terminal 3 and test box socket
56
Wire resistance: Max. 1.5
- Additionally check wires for short to
one another.
Terminal 3 and test box socket
34
Terminal 3 and test box socket
33
Terminal 2 and test box socket
34
Specification: (no continuity)

If no wiring malfunction is detected:

- Loosen knock sensor and tighten

again to 20 Nm (15 ft lb).

If the malfunction is still present (stored

again in DTC memory):

- Replace knock sensor.

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28-19

Ignition coil, checking

Special tools, testers and auxiliary items

Multimeter (Fluke 83 or equivalent)

VW 1594 connector test kit

Test sequence

- Disconnect harness connector and high-voltage

cable from ignition coil N152.

- Check primary resistance with between

terminals 1 and 15 with multimeter.
Specification: 0.5-1.2
- Check secondary resistance between terminals
4 and 15 with multimeter.
Specification: 3-4 k

If the specifications are not attained:

- Replace ignition coil N152.

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28-20

Ignition coil power output stage,

checking

Special tools, testers and auxiliary items

VAG 1598/18 test box

Multimeter (Fluke 83 or equivalent)

VAG 1527B voltage tester

VW 1594 connector test kit

Wiring diagram

Checking voltage supply

- Disconnect 3-pin harness connector from

ignition coil.

- Connect multimeter to measure voltage between

connector terminals 1 and 3 using adapter
cables from VW 1594 test kit.
- Switch ignition on.
Specification: Min. 9 volts

If no voltage is present:

- Switch ignition off.

- Check wire for open circuit between 3-pin
connector terminal 1 and ground, according to
wiring diagram.
Wire resistance: Max. 1.5

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28-21

- Connect VAG 1598/18 test box to

ECM wiring harness.
- Check wire for open circuit between
test box socket 38 and 3-pin
connector terminal 3, according to
wiring diagram.
Wire resistance: Max. 1.5

Checking activation

- Disconnect harness connector for

fuel injectors 1 and 4, and remove
fuse 18.

- Connect VAG 1527B voltage tester

to connector terminals 2 and 3 using
adapter cables from VW 1594 and
VW 1594/15 adapter.
- Operate starter and check ignition
signal from Motronic ECM.
LED must flicker
- Switch ignition off.

If LED does not flicker:

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28-22

- Connect VAG 1598/18 test box to

ECM wiring harness.
- Check wire for open circuit between
test box socket 8 and 3-pin
connector terminal 2, according to
wiring diagram.
Wire resistance: Max. 1.5
- Additionally check wires for short to
one another.
Specification: (no continuity)

If no wiring malfunction is detected and

voltage was present between terminals
1 and 3:

- Replace Motronic ECM J220 page

24-9 , item 16 .

If the voltage supply and activation is

OK:

- Re-connect 3-pin connector and

high-voltage cable to coil.

- Connect VAG 1527B voltage tester

to coil terminals 1 and 15.

WARNING!

During the test, DO NOT touch the

ignition coil terminals or the high-
voltage cables.

- Operate starter.
LED must flicker
- If necessary replace ignition coil
power output stage N157.

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