FUEL INJECTION-MoTRONIC (1.

8L ENGINE) 24a-1

24a Fuel Injection-Motronic

(1.8L engine)
GENERAL 24a-1 Engine coolant temperature (ECT) sensor,
Safety Precautions 24a-2 measuring resistance 24a-7
Fuel injection system components,
ON BOARD DIAGNOSTICS 24a-3 removing and installing 24a-8
Adaptation 24a-4 Intake air temperature (IAT) sensor,
measuring resistance 24a-1 0
Readiness codes 24a-4
Air cleaner assembly 24a-11
Engine control module coding 24a-5
Fuel rail and injector assembly 24a-12
MOTRONIC ENGINE MANAGEMENT Engine Control Module (ECM) 24a-13
COMPONENTS 24a-5 Engine speed (RPM) sensor 24a-13
Fuel injection system
TABLES
component locations, overview 24a-6
a. Readiness code values 24a-4

GENERAL

This repair group covers fuel injection/engine management

system for the 1.8 liter turbo gasoline engine. Operation of
the Bosch Motronic ME7.S engine management system is
described in 2 Fuel, Ignition and Exhaust Systems.

Special testing equipment may be necessary for some of

the tests and repair procedures given here.

Engine Code
AWO, AWW, AWP Motronic ME 7.5

NOTE-
1.BL engines are equipped with versions of the Bosch
Motronic ME7.5 engine management system which is
aBO /I compliant. It is recommended that fault diagnosis
and troubleshooting be carried out using Volkswagen
scan tools VAG 1551/1552, diagnostic computer VAS
5051/5052, or equivalent scan tool or computer program.

Fuel pump and fuel tank testing and repair along with EVAP
information is covered in 20 Fuel Storage and Supply.

Ignition system testing and repair is covered in 28a Ig-

nition System-Gasoline.

Related systems such as Exhaust Gas Recirculation

(EGR) and catalytic converters are covered in 26 Ex-
haust System and Emission Controls.

The Motronic ME7.S system combines ignition, fuel injection

and electronic accelerator pedal functions into one system
managed by a single Engine Control Module (ECM). The
system is fully adaptive and features built-in diagnostics that
are capable of detecting and storing coded fault information.
There are no basic adjustments or settings that can be
made to the system without specialized equipment.
GENERAL
24a-2 FUEL INJECTION-MoTRONIC (1.8L ENGINE)

Safety precautions

The following warnings should be adhered to whenever

working on the engine management system.

WARNING-
Fuel may be discharged during fuel system re-
pairs. 00 not smoke or work near heaters or other
fire hazards. Have a fire extinguisher handy.
Work only in a well-ventilated area.

Wear suitable hand and eye protection when

working with gasoline. Prolonged contact with
fuel can cause illness and skin disorders.

Fuel hoses in engine compartment must only be

secured with spring-type clips. The use of clamp
or screw-type clips will damage fuel lines and
cause fuel leaks.

Connect and disconnect wires and test equip-

ment only with the ignition switched off.

Before making any electrical tests that require

the engine to be cranked using the starter, dis-
able the ignition system as described in 28a Igni-
tion System-Gasoline.

00 not use sealants containing silicones. Parti-

cles of silicone drawn into the engine will not be
burned in the engine and will damage the heated
oxygen sensor. Use only sealants and engine
chemicals marked as safe for oxygen sensors.

During testing, it is possible for the Engine Con-

trol Module to recognize and store a diagnostic
trouble code (oTC) that was due solely to the
testing procedure. Therefore, after completing re-
pairs, the oTC memory must be checked and
erased as necessary with Volkswagen scan tools
VAG 1551/1552, diagnostic computer VAS
5051/5052, or equivalent scan tool or computer
program.

Cleanliness is essential when working on the fuel

system. Thoroughly clean fuel line connections
and surrounding areas before loosening. Avoid
the use of compressed air. Avoid moving the ve-
hicle. Only install clean components.

Disconnecting the negative (-) battery cable may

erase fault codes and basic settings in the engine
management and automatic transmission control
modules. Some driveability problems may beno-
ticed until the system re-adapts to operating con-
ditions. OBo II readiness codes, which may be
required for emissions testing, may also be
erased. Convenience electronics (alarm system,
interior light control, power locks, mirrors, and win-
dows) may need to be re-set using Volkswagen
scan tools VAG 1551/1552, diagnostic computer
VAS 5051/5052, or equivalent scan tool or com-
puter program.

GENERAL
FUEL INJECTION-MoTRONIC (1.8L ENGINE) 24a-3
ON BOARD DIAGNOSTICS (OBD)

On Board Diagnostics, found on the Bosch Motronic

ME7.5 Engine Management Systems monitor most as-
pects of engine operation. The current generation aBO II
is integrated into all North American market Volkswagen
gasoline engines. For a description of the system and an
overview of operation, see 2 Fuel, Ignition, and Ex-
haust Systems. Because of the large number of operat-
ing parameters monitored and the vast quantity of data
available, fault diagnosis can only be properly carried out
using a suitable scan tool such as the Volkswagen scan
tools VAG 1551/1552, diagnostic computer VAS
5051/5052, or equivalent scan tool or computer program.
The engine control module or ECM also supports certain
limited functions in a government-mandated generic
scan tool mode. These functions are standardized for all
aBO II compliant vehicles, but are not as comprehensive
as those found by using the Volkswagen scan tools VAG
1551/1552, diagnostic computer VAS 5051/5052, or
equivalent scan tool or computer program in the propri-
etary mode of operation.

During repairs where the battery must be disconnected,

consideration must be given to the effect that this will
have on the vehicle in general and the engine manage-
ment system in particular.
Diagnostic Trouble Codes may be erased.
Readiness codes may be erased.
Fault counters that monitor certain functions will be re-
set to zero.
Adaptive leaning values will be set to default.

Because the ignition, fuel injection, accelerator system

and emission control functions are even more inter-relat-
ed than on previous Motronic versions, it is difficult, if not
impossible to isolate general driveability problems by ex-
amining individual components of the system. For this
reason, a suitable scan tool must be used for diagnosis if
driveability problems occur or if the malfunction indicator
light (MIL) or E-Gas System lights (EPC) are illuminated.

<iiiiii( Access for the scan tool is through the Data Link Con-
nector (OLe) (arrow) under the lower left side of the in-
strument panel.

ON BOARD DIAGNOSTICS (OBD)

24a-4 FUEL INJECTION-MoTRONIC (1.8L ENGINE)
Adaptation

The Motronic ME7.5.1 engine management system is

adaptive. Idle speed, ignition timing, injection timing and
quantity automatically compensate and adapt to changes
in the engine due to wear and operating conditions. Minor
problems such as mixture changes due to small vacuum
leaks can be eliminated. As a result, idle speed, fuel mix-
ture (Co%) and ignition timing are non-adjustable.

NOTE-
Beginning in 1994 (1993 in California) automakers are
required by law to apply uniform terminology, words
and terms for certain components according to SAE
standard J1930. These standardized terms are used
throughout this section.

Readiness Codes

Federal and state legislation requires that all auto manu-

facturers build into their engine management systems the
ability to check for proper operation of up to 8 functions.
For the ME7.5 engine management system, the exact
number depends on the equipment level of each particu-
lar vehicle. Most of the time, the readiness code will set it-
self after the appropriate conditions have been met.
These may include a cold or a hot start, operation at a cer-
tain load or speed for a certain period of time, or operation
at different temperatures. After repairs, it may be advan-
tageous to confirm repairs rather than wait to see if they
set on their own. Other than waiting, the only other meth-
od of setting the readiness codes on the Motronic ME7.5
system is with a scan tool. This method requires Volk-
swagen scan tools VAG 1551/1552, diagnostic computer
VAS 5051/5052, or equivalent scan tool or computer pro-
gram. and extensive knowledge of the operation and ca-
pabilities. Readiness codes are then generated
according to instructions provided by the scan tool manu-
facturer. For the significance of the 8 digit readiness
code, see Table a.

Table a. Readiness code values

Digit position
Diagnostic Function
1 2 3 4 5 6 7 8
0 Three Way Catalyst
0 Catalyst Heating (always 0)

0 Evaporative Emissions System

(Fuel tank vent system)

0 Secondary Air Injection System

0 Air Conditioning

0 Oxygen Sensor

0 Oxygen Sensor Heater

0 Exhaust Gas Recirculation - EGR

(always 0)

ON BOARD DIAGNOSTICS (OBD)

FUEL INJECTION-MoTRONIC (1.8L ENGINE) 24a-5
The readiness code can be displayed in any of several ar-
eas within the ECM's diagnostic memory depending on
the individual scan tool. It will always have a format con-
sisting of 8 digits. If the 8 digit code contains characters
other than the number 0, such as 10100110, than the
readiness code is NOT set. When the code displays all
zeros, i.e. 00000000, the readiness code IS set and no
further action is required. The specifics of Table a apply
to the 1.8L engine only. While the format is required to be
the same for all engines, certain equipment may not be
used on each engine. For example, the 1.8L engine does
not use EGR and as such, digit number 8 will always
show O. Other engines that use EGR, such as the 1.9L
diesel, will show either a 1 or a 0 as appropriate.

Engine control module coding

The engine control module (ECM) must be supplied with

appropriate power sources and grounds to function prop-
erly. Also, the engine control module must "know" what
equipment is installed in the vehicle. This process is
known as coding and must be performed whenever the
ECM is replaced as new ECM's are un-coded. If an ECM
is moved between vehicles such as might be the case for
diagnostic testing, the coding will need to be changed if
equipment is different. Coding memory is, however, re-
tained when the battery is disconnected. If a new ECM is
installed without being coded, the engine will usually run
poorly and the automatic transmission and anti-lock brak-
ing system (if equipped) will not function properly. The
MIL will be illuminated.

In some cases, this coding process can be done with Volk-

swagen scan tools VAG 1551/1552, diagnostic computer
VAS 5051/5052, or equivalent scan tool or computer pro-
gram. Most later vehicle ECMs can only be coded with
the diagnostic computer VAS 5051/5052. The appropri-
ate code is electronically programmed into the ECM ac-
cording to instructions provided by the scan tool
manufacturer. See the Scan Tool section at the back of
this manual for ECM coding information.

MOTRONIC ENGINE MANAGEMENT

COMPONENTS

The following pages show assembly views of the major

underhood fuel injection components.

NOTE-
Volkswagen identifies electrical components by a letter
and/or a number in the electrical schematics. See 97
Wiring Diagrams, Fuses and Relays. These electri-
cal identifiers are listed in parenthesis as an aid to elec-
trical troubleshooting.

MOTRONIC ENGINE MANAGEMENT COMPONENTS

24a-6 FUEL INJECTION-MoTRONIC (1 .8L ENGINE)
Fuel injection system
1 3 4 5 6 7 8 9 10 11 12 13 14
component locations,

~~r\
overview
1. Evaporative Emissions (EVAP)
Canister purge regulator valve
1 (N80)

2. Camshaft Position (CMP) sen-

sor 2 (G163)

3. Ignition coils with power output

stage (N70, N127, N291, N292)
Individual coil for each cylinder
4. Engine Control Module (ECM)
(J220)

5. Wastegate bypass regulator

valve (N75)

6. Mass Air Flow (MAF) sensor

(G70)

7. Secondary Air Injection (AIR)

pump relay (J299)

8. Heated oxygen sensor (H02S)

(G39)
Before catalyst, B1S1
9. Harness connector (black)
For Oxygen sensor and 028
heater before (pre) catalyst
Engine code AWO: 4-pin
Engine code AWW, AWP: 6-pin
10. Heated oxygen sensor (H02S)
(G130)
After catalyst, B1S2
11. Harness connector (4-pin)
AWO, brown
AWW, AWP, black
For Oxygen sensor and 028
heater after (post) catalyst
12. Clutch pedal position switch
(F36), brake light switch (F) and
brake pedal position switch
13. Air cleaner assembly
14. Battery cover
15. Engine Coolant Temperature
(ECT) sensor (G62)
See Engine coolant tempera-
ture (ECT) sensor, measuring
resistance
16. Camshaft adjustment valve 2
(N208)
Engine code AWW, AWP only
17. Fuel pressure regulator
Location: on fuel rail
26
18. Screw
Tighten to 10 Nm (7 ft-Ib)
19. Engine Speed (RPM) sensor
(G28)
20. O-ring
Always replace
21. Bolt
Tighten to 20 Nm (15 ft-Ib)
Tightening torque influences
function of knock sensor
22. Knock Sensor (KS) 2 (G66)
23. Harness connector, knock sen-
sor2
Engine code AWO: 3-pin
AWO engine has both knock
sensor connectors (square) and
engine rpm sensor connector
(grey, oval shaped) mounted to-
gether
Engine code AWW, AWP: 2-pin
24. Recirculation valve for turbo-
charger (N249)
25. Secondary Air Injection (AIR)
solenoid valve (N112)
24~j]1~~816
25 23 22 20 19 17 15
I M24-0113 I
26. Secondary Air Injection (AIR)
pump motor (V101)
27. Knock Sensor (KS) 1 (G61)
28. Harness connector, knock sen-
sor1
Engine code AWO: 3-pin
AWO engine has both knock
sensor connectors (square) and
engine rpm sensor connector
(grey, oval shaped) mounted to-
gether
Engine code AWW, AWP: 2-pin
29. Fuel injectors (N30, N31, N32,
N33)
30. Intake Air Temperature (IAT)
sensor (G42)
31. Power steering pressure switch
(F88)
32. Throttle Valve (TV) control
module (J338)
For Electronic Pedal Control,
EPC, (E-Gas System)
33. Charge air (boost) pressure
sensor (G31)

MOTRONIC ENGINE MANAGEMENT COMPONENTS

 FUEL INJECTION-MoTRONIC (1.8L ENGINE) 24a-7
Engine coolant temperature (ECT)
sensor, measuring resistance
~ Several different version engine coolant temperature
sensors were installed in 1.8L engines. The early style
sensor (right) was blue and square shaped. The later
style sensor (left) is longer, oval shaped, and either
green or black. Use the illustrations below to determine
which style sensor is installed.

~ Measure resistance at terminals 1 and 3 on early style

ECT sensor.

3----.-.................

I N23-0023 I

~ Measure resistance at terminals 3 and 4 on later style

sensor.

1 r~~~-3

2 --v::===::;~~~L-::"""""'-----'-:'-"'~ 4

I N24-1019 I

kQ
~ Compare ECT resistance reading to graph at left.
Scale A shows resistance for coolant temperature
range 0-50C (32-122F)
7 I--+---+-----l-+--+-+-t-+_+_~
Scale B shows resistance for coolant temperature
range 50-100C (122-212F)
Example:
5 30C corresponds to 1500-2000 Q
80C corresponds to 275-375 Q
4

MOTRONIC ENGINE MANAGEMENT COMPONENTS

24a-8 FUEL INJECTION-MoTRONIC (1.8L ENGINE)
Fuel injection system
41
components, removing and
installing
1. Air filter assembly
See assembly view given later

2. Bolt
Tighten to 10 Nm (7 ft-Ib)

3. Bolt
Tighten to 6 Nm (52 in-Ib)
4. Vacuum connection
To intake manifold
5. ECM harness connector (40-pin)
Terminals 82 to 121
Only disconnect or connect with
ignition switched OFF

6. ECM harness connector (81-pin)

Terminals 1 to 81
Only disconnect or connect with
ignition switched OFF

7. Engine control module (ECM)

(J220)
Location: in air plenum at for-
ward part of instrument panel
near base of the windshield on
driver's side
Must be matched to throttle
valve control module (J338) M24-0114 I
with a scan tool if replaced

8. Harness connector (black)
For Oxygen sensor and 02S
heater before (pre) catalyst
Engine code AWD: 4-pin
Engine code AWW, AWP: 6-pin
For pre-catalyst heated oxygen
sensor (G39) and
oxygen sensor heater (Z19)
Right underside of vehicle in
plastic shield
9. Oxygen sensor, pre-catalyst
(G39) (B1S1)
Use VW special tool set 3337,
or equivalent to remove
Monitors combustion efficiency
Location: Threaded into front
exhaust pipe
Tighten to 50 Nm (37 ft-Ib)
Coat threads only with high tem-
perature anti-seize G 052 112 A3
Do not allow anti-seize compound
into the slots on the sensor body
10. Harness connector, 4-pin
For post-catalyst heated oxy-
gen sensor (G130) and oxygen
sensor heater (Z29)
Right underside of vehicle in
plastic shield
11. Oxygen sensor, post-catalyst
(G130) (B1S2)
Use VW special tool set 3337,
or equivalent to remove
Monitors catalytic converter effi-
ciency
Location: threaded into rear of
catalytic converter
Tighten to 50 Nm (37 ft-Ib)
Coat threads only with high tem-
perature anti-seize G 052 112 A3
Do not allow anti-seize compound
into the slots on the sensor body
12. Bracket
For recirculation valve for turbo-
charger (N249)
For engine speed (RPM) sensor
(G28) harness connector
AWD engine only
13. Bracket
For engine speed (RPM) sensor
(G28) harness connector
AWW, AWP engine only
14. a-ring
Always replace
15. Engine speed (RPM) sensor
(G28)
See Engine speed sensor,
given later
Inductive type sensor
16. Harness connector, 3-pin
Grey
For engine speed (RPM) sensor
17. Bolt
Tighten to 20 Nm (15 ft Ib)
18. Bolt
Tighten to 45 Nm (34 ft Ib)
19. Support bracket
Between intake manifold and
cylinder block
20. Charge air pressure (boost)
sensor (G31)
Mounted to intercooler
21. Intake manifold
22. Gasket
Always replace
(continued on following page)

MOTRONIC ENGINE MANAGEMENT COMPONENTS

 FUEL INJECTION-MoTRONIC (1.8L ENGINE) 24a-9
Fuel injection system
39 40 41
components, removing and
installing (continued)
23. Hose connection
From evaporative emissions
(EVAP) canister purge regula-
tor valve (N8D)

24. Throttle valve (TV) control mod-

ule (J338)
For Electronic Power Control,
EPG, (E-Gas System)
Must be matched to Motronic
ME7.5.1 engine control module
(J22D) with a scan tool if re-
placed
25. Fuel return line
Secure with spring clips only
Ensure coupling is securely
seated
To fuel delivery unit in fuel tank
26. Fuel supply line
Secure with spring clips only
Ensure coupling is securely
seated
From fuel filter
27. Fuel rail, with fuel injectors
(N30-N33) and fuel pressure
regulator
M24-0114 I
28. Intake air temperature (IAT)
sensor (G42) 34. Engine coolant temperature 39. Wastegate bypass regulator
Location: mounted in intake (ECT) sensor (G62) with gauge valve (N75)
manifold just behind throttle sensor (G2)
valve control module 40. Intake hose
4-pin
See Intake air temperature
(IAT) sensor, measuring re- For engine control module 41. Mass air flow (MAF) sensor
sistance Combined with coolant temper- (G70)
ature gauge sender (G2) for in- 5-pin harness connector
29. Airflow strument panel warning light
Terminal 1 position not used
To pipe between turbocharger
35. Harness connector, 4-pin
and intercooler
Black
30. Airflow For engine coolant temperature
To pipe between turbocharger sensor (G62/G2)
and intercooler
36. Retaining clip
31. Airflow Ensure clip is securely seated
To turbocharger
37. Airflow
32. Airflow To recirculation valve for turbo-
From crankcase breather charger (N249)

33. Airflow 38. To pressure unit (servo) on tur-

From crankcase breather bocharger wastegate
AWW, AWP engine only From turbocharger to intercool-
er connecting pipe
To wastegate bypass regulator
valve (N75)

MOTRONIC ENGINE MANAGEMENT COMPONENTS

24a-10 FUEL INJECTION-MoTRONIC (1.8L ENGINE)
Intake air temperature (IAT) sensor,
measuring resistance
~ Disconnect harness connector and measure resistance
across two terminals of IAT sensor (arrow).

kQ Q ~ Compare reading to graph (bottom):

Scale A shows resistance for intake air temperature
900
range 0-50C (32-122F)
800 Scale B shows resistance for intake air temperature
7 700
range 50-100C (122-212F)
Example:
6 600 30C corresponds to 1500-2000 Q
5 500 80C corresponds to 275-375 Q
4 400

3 300

2 200

100

MOTRONIC ENGINE MANAGEMENT COMPONENTS

 FUEL INJECTION-MoTRONIC (1 .8L ENGINE) 24a-11
Air cleaner assembly
1 2 3 4 5 6
1. Bolt
Tighten to 10 Nm (7 ft-Ib)
2. Mass Air Flow (MAF) sensor
(G70)
Terminal 1 position not used
All contacts gold plated
3. Harness connector, 5-pin
All contacts gold plated
4. Seal
Replace if damaged
--1
5. Air cleaner housing, upper sec-
tion

6. Bolt
Tighten to 6 Nm (52 in-Ib)
7. Filter element
Pleated, treated paper
8. Air cleaner housing, lower sec-
tion

9. Duct, intake air

10. O-ring
Replace if damaged
11. Intake hose
6 9
From air cleaner housing upper M24-0079 I
section to secondary air injec-
tion pump intake
Ensure hose is seated tightly
Press together at front to re-
lease

MOTRONIC ENGINE MANAGEMENT COMPONENTS

24a-12 FUEL INJECTION-MoTRONIC (1.8L ENGINE)
Fuel rail and injector
assembly
1. Fuel rail

2. Retaining clip 7 6
Ensure it is securely seated
3. O-ring
Replace if damaged
4. Fuel pressure regulator
Fuel pressure regulator with re-
sidual check valve

5. Connecting hose
To intake manifold
6. Bolt
Tighten to 10 Nm (7 ft-Ib)
7. Fuel return line/hose 1
Secure with spring clips only
Ensure coupling is securely
seated
To fuel delivery unit in fuel tank
8. Fuel supply line/hose
Secure with spring clips only 9 10 11 0024336
Ensure coupling is securely
seated
From fuel filter
9. Retaining clip
Ensure it is securely seated
10. Fuel injectors (N30, N31, N32,
N33)
2-pin harness connector
11. O-ring
Always replace
Moisten with clean engine oil or
fuel before installing

MOTRONIC ENGINE MANAGEMENT COMPONENTS

 FUEL INJECTION-MoTRONIC (1 .8L ENGINE) 24a-13

Engine Control Module (ECM)

~ The engine control module (arrow) is located in the air
plenum near the base of the windshield in the engine
compartment. Access to the ECM requires removal of
the windshield wiper arms and the air plenum cover.

Engine speed (RPM) sensor

Operation of the engine management system depends
on a wide variety of input sensors. Failure of most of
these sensors will allow the engine to continue to run, al-
beit poorly. One major exception to this is the engine
speed sensor (G28). Failure of this sensor will prevent
the engine from starting and running and will set a diag-
nostic trouble code in the ECM.

Note that most diagnostic functions require the use of a

scan tool such as the Volkswagen scan tools VAG
1551/1552, diagnostic computer VAS 5051/5052, or
equivalent scan tool or computer program, however a
quick check can be accomplished as follows:

Disconnect grey 3-pin harness connector from the engine

speed sensor plug near the secondary air injection pump.

Engine code AWD

Engine speed sensor harness connector (A), with ter-
minal identification, shown unplugged at multiple har-
ness connector. Oxygen sensor connectors are on left
and right.

/ I N24-0759I
Engine code AWW, AWP
Engine speed sensor and harness connector (A), with
terminal identification, shown unplugged.

Connect an accurate ohmmeter between terminals 2 and

3 on sensor and measure resistance.

Measure resistance between terminals 1 and 3, and be-

tween terminals 1 and 2 as well. Compare readings to
specification.

Specification
Engine speed sensor resistance values, (1.8L engine)
Between terminals 2 and 3 730 to 1000 Q
Between terminals 1 and 2 infinity Q
Between terminals 1 and 3 infinity Q

If specification is not obtained, replace engine speed

sensor.

If specification is obtained, and engine will not start, ad-

ditional testing with a suitable scan tool will be required.

MOTRONIC ENGINE MANAGEMENT COMPONENTS