Injection System, Servicing

Component locations, overview





1 - Air cleaner
- Disassembling and assembling. Service and Repair
2 - Oxygen sensor 1 before catalyst (G39)*, 50
3 - Oxygen sensor 2 after catalyst (G130), 50 Nm
4 - Coolant temperature sender (G62)*
5 - Divert air valve (N249)*/**
6 - Secondary air inlet valve (N112)*/**
Secondary air system; Removing and installing parts of secondary air system.
7 - Throttle valve control module (J338)*
- Tighten to 10 Nm
- after replacing, adapt Engine Control Module (ECM). Testing and Inspection
8 - Clutch pedal switch (F36)*, Brake light switch (F)*, Brake pedal switch (F47)* and Accelerator position senders (G79 and G185)*
- In driver's footwell
9 - 4 pin connector
- Black for Oxygen sensor 1 before catalyst (G39) and Oxygen sensor heater (Z19)
10 - 4 pin connector
- Brown for Oxygen sensor 2 after catalyst (G130) and Oxygen sensor heater (Z19)
11 - 3 pin connector
- Grey for engine speed sender (G28)
12 - 3 pin connector
- Green for knock sensor 1 (G61)
13 - 3 pin connector
- Blue for knock sensor 2 (G66)
14 - Secondary air pump motor (J299)*/**
Secondary air system; Removing and installing parts of secondary air system.
15 - Engine control unit*
(Motronic control unit -J220)
16 - Intake air temperature sender (G42)*
- Tighten to 10 Nm
17 - Engine speed sender (G28)*
- Inductive sender
- Tighten to 10 Nm
18 - Charge pressure sender (G31)*
19 - Knock sensor 2 (G66)*
- See item 19.
20 - Knock sensor 1 (G61)*
- See item 20.
21 - Fuel pressure regulator
22 - Hall sender (G163)*
See item 11.
23 - Injectors (N30-N33)*
24 - Ignition coil with output stage (N70, N127, N291, N292)
- See item 2.
25 - Charge pressure control solenoid valve (N75)*/**
- Charge pressure system:
Checking charge pressure system. Testing and Inspection
Checking charge pressure control solenoid valve. Testing and Inspection
26 - Ground connection
- On right engine support
27 - Mass air flow sensor (G70)*
28 - Secondary air pump motor (V101)*
Removing and installing parts of secondary air system.
29 - Activated charcoal filter solenoid valve 1 (N80)*/**
Activated charcoal filter system.

Fuel injection, general notes

- The engine control unit is equipped with On Board Diagnostic (OBD). Before carrying out repairs and fault finding the DTC memory must be checked. Also the vacuum hoses and connections must be checked (unmetered air).
- Fuel hoses in engine compartment must only be secured with spring type clips. The use of clamp or screw type clips is not permissible.
- Components marked with * are checked via the On Board Diagnostics, checking and erasing DTC memory. Testing and Inspection
- Components marked with **can be checked with the Output Diagnostic Test Mode. Testing and Inspection
- For trouble-free operation of the electrical components, a voltage of at least 11.5 V is necessary.

NOTES:
- Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the engine and damage the Oxygen sensor
- During some checks it is possible that the control unit will recognise and store a fault. After completing all checks and repairs the DTC memory must be checked and if necessary erased. Testing and Inspection

Safety precautions. Technician Safety Information
Rules for cleanliness. [1][2]Technician Safety Information