Get Ignitionsystem -> 1 Ignition system - repair Guide for Volkswagen Fox SUV Second Generation (2003-2021)

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

28 – Ignition system

1

Ignition system - repair

General indications about the ignition system

♦ The Engine control unit -J623- is equipped with self-diagnosis.

♦ Minimum voltage of 11.5V is necessary for the perfect opera‐

tion of electric components.

♦ In certain checks, the Engine control unit -J623- might identify

a fault and record it on the memory. For that reason, at the end

of all check and repair works, check the fault memory and

erase it, if necessary.

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Ignition system components - remove and install ⇒ page 109 .

Ignition coils with final power stages - remove and install

⇒ page 110 .

Safety measures ⇒ page 111 .

Test data, Spark plugs -Q- ⇒ page 112 .

1.1

Ignition system components - remove and install

1 - Ignition coil 1 with power fi‐

nal stage -N70-

❑ Ignition coil 2 with power

final stage -N127-

❑ Ignition coil 3 with power

final stage -N291-

❑ Remove and install with

Puller -T 10094-

⇒ page 110 .

2 - Ignition coil connector

❑ Black, 4 poles.

3 - Knock sensor 1 -G61- con‐

nector

❑ Black, 2 poles.

❑ Golden connector con‐

tacts.

4 - 20 Nm

❑ Tightening torque influ‐

ences Knock Sensor 1 -

G61- operation.

5 - Knock sensor 1 -G61-

❑ Golden connector con‐

tacts.

6 - 10 Nm

7 - Connector

❑ Black, 3 poles.

❑ For Hall Sensor -G40- .

8 - Hall Sensor -G40-

9 - Sealing ring

❑ Replace if damaged

1. Ignition system - repair

109

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

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10 - Connector

❑ Black, 3 poles.

❑ For Oil level and temperature sensor -G266- .

❑ Not applicable.

11 - Oil level and temperature sensor -G266-

❑ Not applicable.

12 - 8 Nm

13 - Spark plug, 30 Nm

❑ Remove and install with Spark plug wrench -3122 B- .

❑ Type and inter-electrode gap ⇒ page 112

1.2

Ignition coils with final power stages -

remove and install

Special tools and workshop equipment required

♦ Hook -T10118-

♦ Puller -T10094-

110

Rep. Gr.28 - Ignition system

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

Removal

– Install the Extractor -T10094- over the ignition coil with final

power stage.-arrow-

– Install the Hook -T10118- as illustrated.

– Unlock the connector block carefully and remove the connec‐

tor.

– Remove ignition coil with final power stage.

Installation

– Install the Extractor -T10094- over the ignition coil with final

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power stage.

– Install the ignition coil with final power stage in the -arrow- di‐

rection on the engine cylinder head.

– Connect the connector to the ignition coil with final power

stage until fitting it audibly.

1.3

Safety measures

To prevent injuries in people and/or destruction of the injection

and ignition system, take into consideration the following:

♦ Do not touch nor disconnect ignition cables with the engine in

operation or upon start.

♦ Only connect or disconnect the injection and ignition system

cables, including measurement device cables, with the ignition

switched off.

If during a test drive, it is necessary to use test and measuring

equipment, observe the following:

♦ The measurement and test devices must be fastened to the

back seat and operated by another mechanic from then on.

If the measurement and test devices are operated from the front

passenger seat, the person seating there could be injured by the

passenger airbag being triggered, in case of an accident.

♦ To make the engine rotate with the starter, without running it:

– Disconnect all 4-pole connectors -arrows- for the ignition coils.

1. Ignition system - repair

111

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– Remove fuse 33 from fuse holder.

Note

Removing fuse 44, the voltage supply to the injection valves is

interrupted.

1.4

Test data, Spark plugs -Q-

Engine identification letters

BMD/CHFB

Ignition order

1-2-3

BOSCH

101 905 601 B

F 7 HER2

0.8...0.9 mm

30 Nm

1-2-3

NGK

101 905 617

ZFR5P-G

0.8...0.9 mm

30 Nm

Spark plugs ^{13) 12)}

VW/Audi

Manufacturer reference

Inter-electrode gap

Tightening torque

12) Current values and replacement intervals of the Spark plugs -Q- : ⇒ Exhaust

gas Test Folder.

13) Remove and install Spark plugs -Q- with Spark plug wrench -3122B- .

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12.09

112

Rep. Gr.28 - Ignition system

Ignitionsystem -> 1 Ignition system - repair for Your Volkswagen Fox SUV Second Generation (2003-2021)

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