Contents: General instructions for the…↓ Removal and installation of ignition…↓ Installation ↓ Security measures ↓
General instructions for the ignition system
The engine control unit "J623" has a self-diagnosis function. A voltage of at least 11.5 V is required to maintain the faultless operation of the electrical components. During some tests, the engine control unit "J623" may recognize and record an error. Therefore, after all tests and repairs have been completed, it is necessary to interrogate the fault memory and delete any error records that may have been stored in it.
- 1 - Connector, black, 4-pin, unlock with installation tool "T10118"
- 2 - Ignition coil 3 with output stage "N₂91". Ignition coil 1 with output stage "N70". Ignition coil 2 with output stage "N127", Ignition coil 4 with output stage "N₂92"
- 3 - Connector, black, 2-pin, for knock sensor 1 "G61" connector contacts are gold plated
- 4 - Knock sensor 1 "G61" connector contacts are gold plated, for dismantling remove the compressor
- 5 - 20 Nm. Tightening torque affects the operation of the knock sensor
- 6 - Connector, black, 3-pin, for Xonna-G40 sensor-
- 7 - Hall sensor "G40"
- 8 - Sealing ring, replace if damaged
- 9 - 10 Nm
- 10 - Spark plug, 30 Nm, remove and install with spark plug wrench -3122 B-
- 11 - Wiring box, screw to camshaft housing with a torque of 5 Nm
- 12 - Ground wire. Unscrew and screw only with the ignition off
- 13 - 10 Nm. Unscrew and screw only with the ignition off
Removal and installation of ignition coils with output stages
Instructions: The ignition coil housings with power output stages have been modified. Therefore, these ignition coils can only be removed and installed using the puller -T10094 A-. The previously used puller "T10094" can still be used if modified as described below. Using the appropriate equipment, remove metal from the marked area "2" to obtain a new nominal dimension "B" of 18 mm. Add the letter A to the tool designation.
Install the puller -T10094 A- on the ignition coil with the "arrow" output stage.
Pull out the ignition coil with the output stage a little. Place the assembly tool "T10118" as shown in the figure. Carefully loosen the connector lock and disconnect the connector.
Installation
Install the puller -T10094 A- on the ignition coil with the output stage. Put the connector on the ignition coil with the output stage until it clicks into place. Press the ignition coil with the output stage in the direction of the "arrow" into the cylinder head.
Security measures
To avoid personal injury and/or damage to the injection and ignition system, the following requirements must be observed. Do not touch or disconnect high-voltage wires when the engine is running or at starting speed. Disconnecting and connecting electrical cables of the injection and ignition system, as well as measuring instruments, is only permitted when the ignition is switched off. If the engine is supposed to be cranked at starting speed without starting it. Disconnect the 4-pin "arrow" connector from the ignition coils with output stages.
Remove the fuel pump control unit fuse "J538" from the fuse box.
Welding data, spark plugs
| Engine letter designation | BWK |
| Cylinder firing order | 1-3-4-2 |
| Spark plugs | |
| VW-part no | 101 905 626 |
| Distance between electrodes | 0.8...0.9 mm |
| Tightening torque | 25 Nm |
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