VW Golf 3 2e Digifant Injection Ignition Eng

Service
Golf 1992 , Vento 1992 ➤

Digifant Injection and Ignition system (2 valve)
Engine ID 2E
Edition 04.1993
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve)
Repair Group
01 - Self diagnosis, Electrical check
24 - Mixture preparation, Injection
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
Golf 1992 , Vento 1992 ➤
Digifant Injection and Ignition system (2 valve) - Edition 04.1993
Contents
01 - Self diagnosis, Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1 Self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Technical data of self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.4 Connecting fault reader V.A.G 1551 and selecting engine electronics control unit . . . . . . . .2
1.5 Interrogating and erasing fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.6 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.7 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2 Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.1 Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.2 Wiring and component check with test box V.A.G 1598/18 . . . . . . . . . . . . . . . . . . . . . . . . . .9
24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

1 Digifant injection and ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.1 Digifant injection and ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.2 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3 Servicing injection part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.7 Idling check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.8 Checking Lambda probe and Lambda control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
1.9 Checking acceleration/full throttle enrichment and overrun cut-off . . . . . . . . . . . . . . . . . . . .38
1.10 Checking engine operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.11 Checking throttle valve potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
1.12 Matching automatic gearbox control unit and throttle valve potentiometer to one another . . 42
1.13 Checking coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
1.14 Checking intake air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
1.15 Checking air mass meter potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
1.16 Checking control unit voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
1.17 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
1.18 Checking cold start valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
1.19 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
1.20 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
1.21 Checking intake air system for leaks (unmetered air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
1.22 Checking intake air preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
1.23 Basic throttle valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
1.24 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

1 Digifant injection and ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
1.1 Digifant injection and ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
1.2 Servicing ignition part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
1.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
1.5 Installing distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
1.6 Checking ignition timing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
1.7 Checking Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
1.8 Checking ignition transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
1.9 Checking ignition transformer output stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Contents i
Golf 1992 , Vento 1992 ➤
ii Contents
Golf 1992 , Vento 1992 ➤
01 - Self diagnosis, Electrical check
1 - Self diagnosis
1.1 - Self diagnosis
1.2 - Function
The Digifant control unit (J169) for the injection and ignition system is equipped with a fault memory.
If faults occur in the sensors and components being monitored, they will be stored in the fault memory together
with an indication of the type of fault.
The stored faults are output after initiating the fault display => Page 3 .
This fault memory must be erased once the faults have been eliminated => Page 3 .
Faults like an intermittent open circuit or loose contact, are stored and displayed as follows:
◆ If the faults occur for max. 5 seconds, they will be stored as sporadic faults and as such indicated with the
addendum "SP".
◆ If the faults occur for longer than 5 seconds, they will be stored as faults and displayed, even though the
faults may not be present at that time.
A fault relating to the function of the Lambda control system can only be interrogated after a test drive of at
least 5 minutes duration.
1.3 - Technical data of self diagnosis
Equipped with
◆ Fault memory: Non-volatile memory
◆ Rapid data transfer
Selectable functions
Function Ignition switched Engine idling

on
02 Interrogate fault x x
memory
03 Final control di‐ x -
agnosis
04 Introduction of x x
basic setting
05 Erase fault mem‐ - x
ory
06 End output x x
08 Read measuring x x
value block
1) The displayed figures in this function also the measuring value blocks required are described in the
respective repair procedures.
Volkswagen Technical Site: http://vwts.ru http://vwts.info
1.1 - Self diagnosis 1

Golf 1992 , Vento 1992 ➤
Other measuring value blocks and figures output by the control unit, are currently not required by the
service department.
1.4 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit
• Battery voltage OK.

• Fuse 21 or 22 OK.
• Earth connections on engine and gearbox OK.
(Earth connection engine: on cylinder head).
- Connecting fault reader:
Vehicles ▸07.93
- -> Unclip covers for diagnostic connections below the heating/ventilation controls.
- Connect fault reader V.A.G 1551 with cable V.A.G 1551/1 as follows:
- First connect black plug for the fault reader voltage supply to black diagnostic socket.
-> Indicated on display:

V.A.G - SELF DIAGNOSIS HELP
1 - Rapid data transfer*
2 - Flash code output*
* Appears alternately
Note:
If the display remains blank:
=> Fault reader operating instructions
- Connect white plug to white diagnostic socket. (The blue plug is not required.)
Vehicles 08.93 ▸
2 01 - Self diagnosis, Electrical check

Golf 1992 , Vento 1992 ➤
- -> Open ashtray, remove if necessary and slide cover for diagnostic connections to left -arrow-.
- Connect fault reader with cable V.A.G 1551/3.
- Depending upon desired function:
Switch on ignition
or
Start engine.
- Operate fault reader taking into account the information on the display:
- Input 1 for "Rapid data transfer".
- Input 01 for address word "Engine electronics" and confirm with Q.
-> The fault reader V.A.G 1551 display will show the control unit identification, e.g.:
037906024D DIGIFANT 1.7 1390
Coding
◆ 037 906 024D = Part No. of the control unit (for up-to-date control unit versions see parts catalogue)
◆ DIGIFANT = Injection system (Digifant)
◆ 1.7 = hardware version (build level) of control unit
◆ 1390 = software version (programme level number) of control unit
◆ Coding = Not used at present
- Press ⇒ key.

Rapid data transfer HELP
Select function XX
- Further measures see repair procedures.
1.5 - Interrogating and erasing fault memory

- Connect fault reader V.A.G 1551 and select engine electronics control unit (address word 01); selection is
carried out with engine idling.
=> Page 2
Only when engine does not start:
- Switch on ignition.
- Switch on printer with the Print button

(Warning lamp in button lights up).

Select function XX
- Input 02 for "Interrogate fault memory" function and confirm with Q.
If no fault is stored:
- Press ⇒ key.

Select function XX
- Input 06 for "End output" function and confirm with Q.
If one or more faults are stored:
-> The number of faults stored will be shown on the display.
1.4 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit 3
Golf 1992 , Vento 1992 ➤
X Faults recognised!
Note:
If something different is indicated on the display:
The faults stored will be displayed and printed out one after the other.
Then the display will show:

- Switch off ignition
- Locate and eliminate faults printed out as per fault table => Page 4 .
- Input 01 for address word "Engine electronics" and confirm with Q.
- Press ⇒ key.

Select function XX
- Input 02 for "Interrogate fault memory" function and confirm with Q.

- Press ⇒ button until

Select function XX
- Input 05 for "Erase fault memory" function and confirm with Q.

Rapid data transfer
Fault memory is erased!
- Press ⇒ key.

Select function XX

- Carry out road test of at least 5 minutes duration.
When doing this
- The coolant temperature must reach at least 80 °C,
- The engine speed must be increased to at least 3000 rpm,
- The accelerator pedal must be floored briefly.
- Again interrogate fault memory.
Note:
If a fault is present which is not recognised by the self diagnosis, carry out further fault finding using the fault
table in "Engine fault finding" binder.
1.6 - Fault table
Notes:
◆ The fault table is listed according to the 5 digit fault code on the left.

Golf 1992 , Vento 1992 ➤
◆ Before renewing components indicated as being faulty, check the wiring and connectors to these compo‐
nents as well as the earth connections using current flow diagram. This is particularly relevant if faults are
output as "occurring sporadically" (SP).
◆ For wiring check, refer also to "Electrical check", => Page 9 .
V.A.G 1551 print-out Possible fault cause Fault elimination

No fault recognised! If a fault is present: Continue fault finding using fault
Fault not recognised by self diag‐ table in "Engine fault finding" bind‐
nosis er.
00518 2212
Throttle valve potentiometer G69
Short to positive Wiring/G69 has short to positive - Check wiring together with G69
=>Page 9 , Test step 13
Open circuit/short to positive Open circuit
G69 defective
00522 2312
Coolant temperature sender G62 defective - Check wiring together with G62
G62 =>Page 9 , Test step 10
Open circuit/short to positive Wiring open circuit

00523 2322
Intake air temperature sender G42 defective - Check wiring and G42 for short to
G42 earth
Short to earth Wiring has short to earth
Open circuit/short to positive G42 defective - Check wiring together with G42
Wiring open circuit
00524 2142
Knock sensor 1 G61 Wiring open circuit/short circuit in - Check wiring to G61
sensor wiring =>Page 9 , Test step 15
No signal G61 defective - Renew G61 =>Page 63
=> Current flow diagrams, Electrical fault finding and Fitting locations binder
00525 2342
Lambda probe G39 G39 defective - Check Lambda probe and Lambda regulation
=>Page 36
No signal Wiring open circuit - Check wiring to G39
Short to positive G39 defective - Check wiring and G39 for short to positive
Wiring has short to positive
00532 2234
Supply voltage Battery voltage above 15.5 V - Check alternator
Signal too high
Signal too low Battery voltage less than 6.1 V - Check battery
=> Current flow diagrams, Electrical fault finding and Fitting locations binder
00545 2314
Engine/gearbox electrical connection Open circuit in lead 31 from Digi‐ - Locate and eliminate open circuit
fant control unit (J169) to automat‐ using current flow diagram
ic gearbox control unit (J217)
No signal
1.6 - Fault table 5

Golf 1992 , Vento 1992 ➤

00552 2323
Air mass meter -G19
Open circuit/short to earth Open/short circuit in wiring, G19 - Check wiring together with G19
defective =>Page 9 , Test step 12
Short to positive Wiring short circuit, G19 defective - Check air mass meter potentiom‐
eter =>Page 45
65535 1111
Control unit defective Components in Digifant control - Renew J169 =>Page 30
unit (J169)
1.7 - Final control diagnosis
Note for Model Year 1992 (N):

Before initiating the final control diagnosis the engine must be switched off for min. 2 minutes. If the 2 minutes
are not observed, it can happen that the current supply relay (J176) remains activated and the engine will not
start. To achieve a normal operation of the Digifant control unit again, pull the current supply relay (J176) with
Ident. No. 30 out of the relay plate for a few seconds (relay position 3).
The final control diagnosis activates the following components in the stated sequence:
1. Fuel pump relay (J17)
2. Idling speed stabilisation valve (N71)
3. Activated charcoal filter solenoid valve 1 (N80)
- Connect fault reader V.A.G 1551 and select engine electronics control unit (address word 01); carry out
selection with ignition switched on.
=> Page 2

Select function XX
- Operate fault reader taking into account the information on the display:
- Input 03 for "Final control diagnosis" function.

Rapid data transfer Q
03 Final control diagnosis
Note:
Actuate fuel pump relay (J17):
- Confirm input with Q button.

Final control diagnosis
Fuel pump relay J17
The fuel pump relay (on the relay plate with fuse box, relay position 12) must click until switching to the next
final control by pressing the ⇒button.

Golf 1992 , Vento 1992 ➤
Note:
During the activation of the fuel pump relay the fuel pump must be heard to run at intervals.
If the relay does not click:
- Check fuel pump relay:
=> Current flow diagrams, Electrical fault finding and Fitting locations; Fuel supply.
Activate idling stabilization valve (N71):
- Press ⇒key.

Idling stabilization valve N71
The idling stabilization valve must click.
If the idling stabilization valve does not click:
- -> Pull plug -1- off valve -2- and connect measuring cable V.A.G 1501 to valve and wiring loom.
- Connect diode test lamp V.A.G 1527 with adapters from V.A.G 1594 to connectors 1 and 3 of the measuring
cable.
LED must flash
LED flashes or lights up:
- Renew idling stabilization valve.
LED does not flash or light up:
- Carry out electrical check, Test step 14

=> Page 9 , renew control unit if necessary.
Activate solenoid valve 1 for activated charcoal filter (N80):
- Press ⇒ button.

Solenoid valve 1 for activated charcoal
filter N80
The solenoid valve (right wheel housing) must click.
1.7 - Final control diagnosis 7

Golf 1992 , Vento 1992 ➤
Note:
Indicated on display even for vehicles without solenoid valve.
If the solenoid valve clicks:
- Press ⇒ button.

Select function XX

Notes:
◆ If ignition is not switched off before trying to start engine, engine will not start as the injectors and ignition
transformer will not have been activated.
◆ If final control diagnosis has to be repeated, switch off ignition, disconnect lead from fault reader for at least
3 minutes, re-connect and carry out final control diagnosis.
If the solenoid valve does not click:
- -> Pull plug off valve and connect diode test lamp V.A.G 1527 with aux. cables from V.A.G 1594 to discon‐
nected plug.
The LED must flash
LED flashes:
- Renew solenoid valve.
LED does not flash:
- Press ⇒ button.

Select function XX

=> Page 9 , renew control unit if necessary.

Golf 1992 , Vento 1992 ➤
2 - Electrical check
2.1 - Electrical check
2.2 - Wiring and component check with test box V.A.G 1598/18
Notes:
◆ Use the hand multimeter V.A.G 1526 or the multimeter V.A.G 1715 and the diode test lamp V.A.G 1527 for
the checks.
◆ The specifications given are valid for an ambient temperature from 0 to + 40 °C.
◆ If the measured figures deviate from the specifications, determine fault using current flow diagram.
◆ If the measured figures only deviate slightly from the specifications, clean sockets and plugs on the tester
and measuring cables, then repeat check. Before replacing components check wiring and connections and
particularly in cases of specifications less than 10ω repeat the resistance measurement on the component.
◆ To connect the testers to the test box use aux. cables from adapter set V.A.G 1594.
◆ The contact numbers of the plugs and the socket numbers in the test box are identical.
◆ Additional to the checks described in the table, if necessary, the wiring must also be checked for short to
earth (-) or battery positive (+).
• Battery voltage OK.

• Fuses 15 and 18 OK.
• Earth connections on engine and gearbox OK.
(Earth connection engine: on cylinder head).
• Fuel pump and fuel pump relay OK.
- -> With ignition switched off pull connector -1- off control unit -2-.
- Connect test box to wiring loom connector.
- Carry out checks as per table => Page 9 .
Attention!
To prevent damage to the electronic components, switch to the respective measuring range before connecting
the measuring cable, observe the test conditions and carry out the additional work listed in the table.
Note:
After completing the electrical check, on vehicles with automatic gearbox, the fault "Engine/gearbox electrical
connection: open circuit"caused by the check and stored in the automatic gearbox control unit must be erased.
=> Automatic gearbox 096; Repair Group 01
Test table
- Measuring range: Switch to voltage measurement -V-.
2.1 - Electrical check 9

Golf 1992 , Vento 1992 ➤
Test step Item checked ▪ Test conditions Test box sockets Specifications1)
- additional work
1 Voltage supply for Digifant control - Switch on ignition 1+8
unit (J169)
1 + 23
- Only vehicles ▸11.91 1 + 38
▪ Ignition switched on
2 Wire to ignition trans. (N152) ▪ Ignition switched on 1+7 app. battery voltage
32) Cold start valve (N17) ▪ Ignition switched on 6+1 app. battery voltage
4 Idling stabilization valve ▪ Ignition switched on 30 + 1 app. battery voltage
(N71)
5 Activated charcoal filter solenoid ▪ Ignition switched on 33 + 1 app. battery voltage
valve 1 (N80)
1) Observe notes => Page 9
2) Cold start valve only on vehicles ▸07.93
▪ Measuring range: Voltage measurement range -V- selected.

- additional work
6 Wire to fuel pump relay (J17) ▪ Ignition switched on bridge Fuel pump must run au‐
with relay 31 + 1 dibly
7 Wire to the injectors ▪ Ignition switched on 1+2 app. battery voltage
(N30...N33)2) Remove fuse 18
Bridge sockets 31 + 1
8 Wire to air conditioning sys‐ ▪ Ignition switched on 1 + 39 app. battery voltage
tem Switch on heater blower
Switch air conditioning
system to maximum
9 Wire from starter terminal 50 ▪ Selector lever in P or N 32 + 1 at least 8 V
Pull connector off Hall
sender (distributor)
Operate starter and then
switch off ignition
2) Checking injector resistance => Page 54
▪ Ignition switched off.

Measuring range: Switch to resistance measurement -ω-.
- additional work
102) Coolant temperature send‐ --- 12 + 35 => Page 12 ,
er (G62) => Fig. 1
11 Intake air temperature --- 35 + 37 => Page 12 ,
sender (G42) => Fig. 1
12 Air flow meter potentiome‐ --- 16 + 35 0.5...1.0 kω
ter (G19)

Golf 1992 , Vento 1992 ➤
- Move air flow meter 14 + 16 Change in resistance with‐

plate or operate starter out interruption
2) If the self diagnosis indicates a sender fault which is not established by this test, it could be caused by a
temporary break in the temperature signal. In this case, additionally check the coolant temperature sender =>
Page 42 .
▪ Ignition switched off

▪ Measuring range: Resistance measurement -ω- selected
- additional work
13 Wiring to throttle valve potenti‐ - Pull 3-pin connector off throt‐ 41 + max. 1.5 ω
ometer (G69) tle valve potentiometer Contact 12)
40 +
Contact 22)
35 +
Contact 32)
14 Wiring to Hall sender - Pull connector off G40 (dis‐ 35 + max. 1.5 ω
(G40) tributor) Contact 13)
44 +
Contact 23)
45 +
Contact 33)
2) On separated connector for G69 => Page 13 , Fig. 3

- additional work
15 Wiring to knock sensor 1 - Separate connector to G61 36 + max. 1.5 ω
(G61) Contact 12)
34 +
Contact 22)
9+
Contact 32)
164) Wiring to Lambda probe - Separate connector to G39 20 + max. 1.5 ω
(G39) Contact 23)
42 +
Contact 33)
17 +
Contact 43)
- Reconnect connector to G39 1 + 17 ∞ω
4) Only on vehicles with catalyst

2.2 - Wiring and component check with test box V.A.G 1598/18 11
Golf 1992 , Vento 1992 ➤
- additional work
17 Wire to white diagnostic socket - Vehicles ▸07.93 43 + Max. 1.5 ω
Contact 2 on white
diagnostic socket (upper)
- Vehicles 08.93 ▸ 43 + Contact 7 on diagnostic
socket
=>Fig. 2
-> Fig. 1 Resistance graph for
◆ Coolant temperature sender (G62)

◆ Intake air temperature sender (G42)
-> Fig.2 Diagnostic connector contact assignment

Golf 1992 , Vento 1992 ➤
-> Fig.3 Lambda probe (G39) connector contact assignment
-> Fig.4 Hall sender (G40) connector contact assignment
-> Fig.5 3-pin connector contact assignment
◆ Throttle valve potentiometer (G69)
-> Fig.6 3-pin connector contact assignment
◆ Knock sensor 1 (G61)
2.2 - Wiring and component check with test box V.A.G 1598/18 13
Golf 1992 , Vento 1992 ➤
24 - Mixture preparation, Injection
1 - Digifant injection and ignition system

1.1 - Digifant injection and ignition system
1.2 - Fitting locations overview

1 4 pin connector
◆ For Lambda probe (G39)
◆ On engine mount - Right
2 Pressure regulating valve for crankcase breather
3 Throttle valve potentiometer (G69)
4 Throttle valve housing
5 Digifant injection and ignition system control unit (J169)
6 Intake manifold
14 24 - Mixture preparation, Injection

Golf 1992 , Vento 1992 ➤
7 Cold start valve (N17)

◆ ▸07.93
8 CO sampling pipe
9 Fuel pressure regulator
10 Fuel rail
11 Injector (N30...N33)
12 Ignition transformer (N152)
◆ =>Page 63
13 Idling stabilization valve (N71)
14 Distributor
◆ =>Page 64
15 Coolant temperature sender (G62)
◆ with coolant temperature indicator sender (G2)
1.2 - Fitting locations overview 15

Golf 1992 , Vento 1992 ➤
16 Knock sensor 1 (G61)

◆ =>Page 63
17 Earth connection
18 Intake hose
19 Temperature regulator
◆ For intake air preheating
20 Air flow meter
◆ With sender for intake air temperature (G42) and potentiometer (G19)
21 Air cleaner
22 Activated charcoal filter solenoid valve 1 (N80)
◆ Activated charcoal filter system
=> Repair group 20, removing and installing parts of the fuel supply system, removing and installing parts of
the activated charcoal filter system
1.3 - Servicing injection part
Servicing ignition part=>Repair group 28

Golf 1992 , Vento 1992 ➤
Notes:
◆ The control unit for the fuel injection and ignition system is equipped with a fault memory. Before carrying
out repairs, adjustment work and fault finding the fault memory must be interrogated and the vacuum con‐
nections checked (outside air).
◆ Components marked with * are checked via the self diagnosis.
=> Page 3 , interrogating and erasing fault memory
◆ Components marked with ** are checked via the final control control diagnosis => Page 6 .
◆ Always renew spring-type hose clips with screw-type hose clips.
◆ For trouble-free operation of the electrical components a voltage of at least 11.5 V is necessary.
◆ Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the
engine and damage the Lambda probe.
Safety precautions =>Page 32

Rules for cleanliness => Page 33
Technical data => Page 33
Self diagnosis and electrical check of the injection and ignition system => Repair group 01
Checking intake system for leaks (unmetered air) => Page 55
I - Removing and installing air cleaner and air flow meter

=> Page 18
1.3 - Servicing injection part 17

Golf 1992 , Vento 1992 ➤
II - Removing and installing throttle valve housing, cold start valve and idling stabilization valve =>
Page 21
III - Removing and installing fuel manifold and intake manifold => Page 27
IV - Removing and installing control unit, Lambda probe and coolant temperature sender => Page
30
Removing and installing air cleaner and air flow meter
A- => Page 27
1 Filter element
2 Air cleaner upper part
3 Air ducting
4 5 Nm
5 Seal
◆ Renew if damaged
6 Connector

Golf 1992 , Vento 1992 ➤
7 Air mass meter*

◆ With sender for intake air temperature (G42) and potentiometer (G19)
◆ After renewing:
Match Digifant control unit to engine by completing idling check
=> Page 33
8 Metal plug
◆ Do not pull out
9 Hose clip
10 Intake hose
11 Hose
◆ To exhaust manifold

Golf 1992 , Vento 1992 ➤
◆ For intake air preheating
◆ Installation position: brass hose connection at bottom
◆ Checking intake air preheating =>Page 56
13 Retaining ring
14 Packing
15 Air ducting
16 Air cleaner lower part
17 Vacuum unit
◆ Checking intake air preheating =>Page 56

Golf 1992 , Vento 1992 ➤
Removing and installing throttle valve housing, cold start valve and idling stabilization valve
B - => Page 27
C - To activated charcoal filter solenoid valve 1 (N80)
◆ => Page 58 , vacuum hose connection diagram
D - => Page 27
E - => Page 27
1 Intake hose

Golf 1992 , Vento 1992 ➤

◆ Throttle valve basic setting => Page 57
◆ After basic setting:
=> Page 42
◆ After renewing:
=> Page 42

Golf 1992 , Vento 1992 ➤
3 O ring
4 Connector
5 Throttle valve potentiometer (G69)*
◆ 3-pin connector for injection and ignition system
◆ 4-pin connector additional on vehicles with automatic gearbox to control unit for automatic gearbox (J217)
◆ Checking => Page 40
◆ After renewing:
=> Page 42

Golf 1992 , Vento 1992 ➤
6 Bolt
◆ Secure with plate or fluid
7 Seal
◆ Renew
8 Intake manifold
9 To activated charcoal filter solenoid valve 1 (N80)
◆ => Page 58 , vacuum hose connection diagram
10 Plug
11 CO take-off pipe
12 10 Nm
13 Connecting hose
◆ On vehicles with ABS
14 Non-return valve

Golf 1992 , Vento 1992 ➤
15 For air conditioner

16 To brake servo
◆ Not on vehicles with ABS
17 Bracket
◆ For vacuum booster
18 Cold start valve
◆ ▸07.93
19 Vacuum booster
◆ On vehicles with automatic gearbox without ABS
20 Temperature switch
◆ For fan run-on, to cool the injectors
◆ Checking:
=> Repair Group 19; removing and installing parts of cooling system; checking radiator fan run-on removing
and installing parts of cooling system checking radiator fan run-on

Golf 1992 , Vento 1992 ➤
21 Support bracket
22 M6 = 10 Nm
M8 = 20 Nm
23 Idling speed stabilization valve (N71)**
◆ Resistance: 2...10 ω

Golf 1992 , Vento 1992 ➤
Removing and installing fuel manifold and intake manifold
A- => Page 18
B- => Page 21
D- => Page 21
E- => Page 21
1 Connecting hose
◆ To crankcase breather
2 Crankcase breather pressure regulating valve
3 Bracket
4 Warm air collector plate
5 25 Nm
6 20 Nm

Golf 1992 , Vento 1992 ➤
7 Return pipe
◆ Blue or blue markings
8 Retaining clip
9 Supply pipe
◆ Black or white markings
10 O ring
◆ Checking fuel pressure regulator and holding pressure => Page 48
12 Seal
13 Fuel manifold upper part
◆ Removing and installing:
=> Page 52 , removing and installing injectors

Golf 1992 , Vento 1992 ➤
14 10 Nm
15 Injectors (N30...N33)
◆ Removing and installing
=> Page 52
16 Fuel rail
◆ Removing and installing:
=> Page 52 , removing and installing injectors
17 Intake manifold
18 Seal
◆ Renew

Golf 1992 , Vento 1992 ➤
Removing and installing control unit, Lambda probe and coolant temperature sender
1 Connector
◆ Only disconnect or connect with ignition switched off
2 Digifant control unit (J169)*
◆ For injection system, Lambda regulation, engine speed governor via fuel pump relay, ignition and self
diagnosis
◆ After renewal:
Match Digifant control unit to engine by completing idling check => Page 33
3 Bracket
4 10 Nm
5 Connector
◆ For Lambda probe and Lambda probe heating

Golf 1992 , Vento 1992 ➤
◆ Check Lambda probe heating voltage supply between contacts -1- and -2- with engine running:
Specification:
approx. battery voltage
◆ Check Lambda probe heating at Lambda probe connector (white wiring) for continuity
◆ Contact 3 - Lambda probe screening
◆ Contact 4 - Lambda control
6 Lambda probe (G39)*, 50 Nm

◆ Fitting location: catalyst
◆ Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
◆ Checking Lambda probe and Lambda control
=> Page 36

Golf 1992 , Vento 1992 ➤
7 Retaining clip
8 Connection
9 O ring
10 Coolant temperature sender (G62)*
◆ With coolant temperature indicator sender (G2)
◆ If necessary before removing, release pressure from cooling system
◆ Resistance values
=> Page 12 , Fig. 1
11 Connector
1.4 - Safety precautions
To prevent injuries to persons and/or damage to the injection and ignition system, the following must be ob‐
served:
◆ Do not touch or pull off ignition wiring when engine is running or turning at starter speed.
◆ The ignition must be switched off when disconnecting or connecting injection and ignition system wiring as
well as test instrument cables.

Golf 1992 , Vento 1992 ➤
◆ If the engine is to be turned at starter speed, without starting, e.g. when checking compressions, pull plug
off Hall sender (distributor).
1.5 - Rules for cleanliness
When working on the fuel supply/injection system, pay careful attention to the following "5 rules":
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
1.6 - Technical data
Engine code 2E
Idling checks2)
Idling speed rpm 770...8701)
CO content Vol.% 0.2...1.21)
Digifant control unit3)
Part No. when renewing=> Parts microfiche
Governed speed rpm 6400...6500
1) Up-to-date specifications:
=> "Emission and idling test" binder
2) Observe test conditions => Page 33
3) Match Digifant control unit to engine after replacement. To do this carry out idling check => Page 33
1.7 - Idling check
Notes:
◆ The work sequence is dependent upon the programme level of the Digifant control unit. Programme level
number => Page 2 , connecting fault reader V.A.G 1551 and selecting engine electronics control unit.
◆ Idling speed and CO content are not adjustable.
◆ The basic setting of the engine is carried out with the fault reader V.A.G 1551.
◆ In the basic setting, the Digifant control unit is matched to the throttle valve potentiometer at idling speed.
The ignition timing control is switched off.
• Engine oil temperature min. 80 °C

• Electrical consumers switched off (radiator fan must not run during the check/adjustment).
• Air conditioner switched off
• Accelerator cable adjustment OK
=> Repair group 20, removing and installing parts of the fuel supply system, adjusting accelerator cable
• Exhaust system must be free of leaks
1.4 - Safety precautions 33

Golf 1992 , Vento 1992 ➤
- -> Connect ignition tester V.A.G 1367 with pick-up clamp V.A.G 1367/8 or ignition tester V.A.G 1767.
- -> Connect CO tester V.A.G 1363A with adapter V.A.G 1363/3 to CO sampling pipe.
- -> Pull off crankcase breather hose at pressure regulating valve and seal hose opening to intake hose -
arrow-.
- Interrogate and erase fault memory, eliminate faults if necessary => Page 3 .
- Press ⇒ button.
- Input 04 for "Initiate basic setting" and confirm with Q.

Initiate basic setting HELP
Input display group number XX
Note:
Input the display group number corresponding to the programme level number of the control unit.
-> Up to programme level number 1083

037906024D DIGIFANT 1.7 1083
Coding
(from programme level number 1390 =>Page 35 )
- Input 00 for "display group number" and confirm with Q-key.

(1...10 = Display zones; the numbers are not relevant for the basic setting)
System in basic setting
⇒
1 2 3 4 5 6 7
8 9 10
- Checking ignition timing at 2000...2500 rpm.

Specification: 4...8° before TDC1)
- If necessary adjust ignition timing by turning the distributor:
Setting figure: 6 ± 1° before TDC1)

Golf 1992 , Vento 1992 ➤
- Allow engine to idle for at least 1 minute.

- End the engine basic setting by pressing the⇒ button. When doing this the radiator fan must not run.
- Check idling speed and CO content.
Idling speed: 770...870 rpm1)
CO content: 0.2...1.2 Vol.%1)
- Press ⇒ button.
- Input 06 for "End output" and confirm with Q.
If the specifications are not obtained:
- Check air intake system for leaks

=> Page 55 .
- Check exhaust system between cylinder head and catalyst including CO sampling pipe for leaks.
- Check Lambda probe and Lambda control
=> Page 36
- Check idling speed stabilization => Page 6 , final control diagnosis.
- Carry out road test, then repeat fault memory interrogation and idling check.
-> From programme level number 1390

037906024D DIGIFANT 1.7 1390
Coding
- Input 01 for display group 01 and confirm with Q.

(1...4 = Display zones)
System in basic setting 1
1 2 3 4
Do not continue with check until 00000000 appears in the 4th display zone.
Note:
◆ If one or more 1s appear in display zone 4, test conditions are not satisfied:
=>Meaning of figures in display zone 4,
Page 36 .
- Checking ignition timing at 2000...2500 rpm.

Specification: 4...8° before TDC1)
- If necessary adjust ignition timing by turning the distributor:
Setting figure: 6 ± 1° before TDC1)
- Allow engine to idle for at least 1 minute.

- End the engine basic setting by pressing the⇒ button. When doing this the radiator fan must not run.
- Check idling speed and CO content.
Idling speed: 770...870 rpm1)
CO content: 0.2...1.2 Vol.%1)
1.7 - Idling check 35

Golf 1992 , Vento 1992 ➤
- Press ⇒ button.
If the specifications are not obtained:

=> Page 55 .
- Check exhaust system between cylinder head and catalyst including CO sampling pipe for leaks.
- Check Lambda probe and Lambda control
=> Page 36
- Check idling speed stabilization => Page 6 , final control diagnosis.
- Carry out road test, then repeat fault memory interrogation and idling check.
Meaning of numbers in display zone 4
The control unit is only in check or adjust mode if 00000000 appears in the 4th display zone (conditions satis‐
fied). the conditions are not satisfied if one or more 1s appear in display zone 4:
◆ 01000000 = Signal from automatic gearbox control unit to Digifant control unit not OK.
◆ 00100000 = Air conditioner not switched off
◆ 00000100 = Throttle valve not closed
◆ 00000010 = Engine speed outside permitted range
◆ 00000001 = Coolant temperature below 85 °C
1.8 - Checking Lambda probe and Lambda control
Note:
The work sequence is dependent upon the programme level of the Digifant control unit. Programme level
• Engine oil temperature min. 80 °C

• Idling check OK., checking => Page 33
• Exhaust system between catalyst and cylinder head free of leaks
• Lambda probe heating voltage supply OK., checking => Page 30
=> Page 2

Select function XX
- Input 08 for "Read measured value block" function and confirm with Q.

Read measured value block HELP

Read measured value block 1
1 2 3 4

Golf 1992 , Vento 1992 ➤
Note:

037906024D DIGIFANT 1.7 1083
Coding
(from programme level number 1390 =>Page 37 )
- Increase engine speed to approx. 2500 rpm for 1 minute, then allow engine to idle.
- Read Lambda voltage in display zone 3. Lambda voltage must fluctuate by
more than 0.3 V.
- Press ⇒ key.
If 0.00 V appears in display zone 3 (earth connection):
- Separate 4-pin connector on Lambda probe and probe heater.
If 0.45 V appears in display zone 3 with connector separated:
- Renew Lambda probe (G39).
- Perform electrical check, test step 16

=> Page 9 . Renew Digifant control unit (J169) if necessary.
If Lambda voltage does not fluctuate by more than 0.3 V (after checking with increased engine speed):

=> Page 9 .

037906024D DIGIFANT 1.7 1390
Coding
Do not continue with check until 00000000 appears in 4th display zone.
Note:
◆ If one or more 1s appear in display zone 4, test conditions are not satisfied:
=>Meaning of numbers in display zone 4,
1.8 - Checking Lambda probe and Lambda control 37

Golf 1992 , Vento 1992 ➤
Page 36 .
- Increase engine speed to approx. 2500 rpm for 1 minute, then allow engine to idle.
- Read Lambda voltage in display zone 3. Lambda voltage must fluctuate by
more than 0.3 V.
- Press ⇒ key.
If 0.00 V appears in display zone 3 (earth connection):
- Separate 4-pin connector on Lambda probe and probe heater.

=> Page 9 . Renew Digifant control unit (J169) if necessary.
If Lambda voltage does not fluctuate by more than 0.3 V (after checking with increased engine speed):

=> Page 9 .
1.9 - Checking acceleration/full throttle enrichment and overrun cut-off

037906024D DIGIFANT 1.7 1083
Coding
Notes:
◆ The following check checks the overrun cut-off. If this check is OK., then the acceleration and full load
enrichment are also OK.
=> Page 2

Golf 1992 , Vento 1992 ➤

Select function XX


1 2 3 4
Note:
Do not continue with test until
• The coolant temperature is above 85 °C

-display zone 1-
• The engine has then run for a further 2 minutes at idling speed
- Note figure in display zone 4.

- Increase engine speed by revving up to at least 3000 rpm (see display zone 2) and release accelerator. The
displayed figure in display zone 4 (injection period) must
increase, drop back to 0 ms and rise again to the noted figure.
- Press ⇒ button.
If the displayed figure does not increase and does not drop back to 0 ms:
- Carry out idling check => Page 33 .

- Check throttle valve potentiometer => Page 40 .
1.10 - Checking engine operating mode

037906024D DIGIFANT 1.7 1390
Coding
Notes:
◆ Recognition of the following operating conditions are checked with this check: idling, part load, full load and
overrun cut-off.
=> Page 2

Select function XX
1.9 - Checking acceleration/full throttle enrichment and overrun cut-off 39

Golf 1992 , Vento 1992 ➤


1 2 3 4
Note:
checking idling recognition:
- Observe 2nd position from left in display zone 4.

Specification: 1 (01000000)
Checking part-load recognition by smoothly increasing throttle:
- Observe 3rd position from left in display zone 4.

Checking full load recognition by briefly opening throttle fully:
- Observe 4th position from left in display zone 4.

Checking overrun operation recognition by briefly increasing engine speed to over 3000 rpm (coolant temper‐
ature above 60 °C):
- Observe 1st position from left in display zone 4.

Specification: 1 (10000000) briefly with throttle valve closed and engine speed above 1200 rpm
- Press ⇒ key.
If the specifications are not attained:
- Interrogate and erase fault memory. Eliminate faults if necessary => Page 3 .
- Check throttle valve potentiometer
=> Page 40 .
1.11 - Checking throttle valve potentiometer
Note:
=> Page 2

Golf 1992 , Vento 1992 ➤

Select function XX


037906024D DIGIFANT 1.7 1083
Coding
(From programme level number 1390 =>Page 41 )

1 2 3 4
Note:
- Slowly open throttle valve and watch angle display in display zone 3.
The figure must increase uniformly over
the complete range.
- Press ⇒ key.
If the figure does not increase uniformly:

=> Page 9 , if necessary renew throttle valve potentiometer (G69).

037906024D DIGIFANT 1.7 1390
Coding

1 2 3 4
Note:
- Slowly open throttle valve and watch angle display in display zone 3.
The figure must increase uniformly over
the complete range.
- Press ⇒ key.
1.11 - Checking throttle valve potentiometer 41

Golf 1992 , Vento 1992 ➤
If the figure does not increase uniformly:

=> Page 9 , if necessary renew throttle valve potentiometer (G69).
1.12 - Matching automatic gearbox control unit and throttle valve potentiometer to one
another
Note:
The automatic gearbox control unit and throttle valve potentiometer must be matched to one another after the
following work has been completed:
◆ Renewal of automatic gearbox control unit

◆ Removing and installing throttle valve potentiometer
◆ Renewal of throttle valve housing
Matching
- Using fault reader V.A.G. 1551 bring system to basic setting:
=> Automatic gearbox 096; Repair Group 01; Self-diagnosis; Introduction of basic setting Self-diagnosis Intro‐
duction of basic setting
1.13 - Checking coolant temperature sender
Note:
• Engine cold
=> Page 2

Select function XX


1 2 3 4

Golf 1992 , Vento 1992 ➤
Note:

037906024D DIGIFANT 1.7 1083
Coding
- Observe coolant temperature figure in display zone 1. The temperature figure must
Increase uniformly and without interruption.
Notes:
◆ If the display on fault reader jumps by 2...5 °C, it is a control unit fault and not caused by a defective sender.
◆ Open circuit is indicated by - 40 °C.
◆ If irregular engine running occurs in certain temperature ranges and the temperature figure does not increase
without interruption, the temperature signal is temporarily interrupted and the sender must be renewed.
- Press ⇒ key.
- In put 06 for "End output" and confirm with Q.
If the temperature figure does not change:
- Carry out electrical check, test step 10

=> Page 9 , if necessary renew coolant temperature sender (G62), (first release pressure from cooling
system).

037906024D DIGIFANT 1.7 1390
Coding
- Observe coolant temperature figure in display zone 2. The temperature figure must
Increase uniformly and without interruption.
Notes:
◆ If the display on fault reader jumps by 2...5 °C, it is a control unit fault and not caused by a defective sender.
◆ Open circuit is indicated by - 40 °C.
◆ If irregular engine running occurs in certain temperature ranges and the temperature figure does not increase
without interruption, the temperature signal is temporarily interrupted and the sender must be renewed.
- Press ⇒ key.

=> Page 9 , if necessary renew coolant temperature sender (G62), (first release pressure from cooling
system).
1.14 - Checking intake air temperature sender
Note:
1.13 - Checking coolant temperature sender 43

Golf 1992 , Vento 1992 ➤
=> Page 2

Select function XX


037906024D DIGIFANT 1.7 1083
Coding

1 2 3 4
Note:
- Note intake air temperature figure in display zone 3.
- -> Lift air filter upper part, spray intake air temperature sender (G42) with commercial refrigerant spray and
observe temperature reading. Temperature must
drop.
- Press ⇒ key.

=> Page 9 , if necessary renew air flow meter with intake air temperature sender (G42) and perform idling
check.

Golf 1992 , Vento 1992 ➤
037906024D DIGIFANT 1.7 1390

Coding

1 2 3 4
Note:
- Note intake air temperature figure in display zone 4.
- -> Lift air filter upper part, spray intake air temperature sender (G42) with commercial refrigerant spray and
observe temperature reading. Temperature must
drop.
- Press ⇒ key.

=> Page 9 , if necessary renew air flow meter with intake air temperature sender (G42) and perform idling
check.
1.15 - Checking air mass meter potentiometer
Note:
• Coolant temperature above 80 °C
=> Page 2

Select function XX
1.14 - Checking intake air temperature sender 45

Golf 1992 , Vento 1992 ➤


037906024D DIGIFANT 1.7 1083
Coding

1 2 3 4
Note:
- Read off displayed figure in display zone 4.

Specification: 10...30 % when idling
the figure must increase when revving-up
- Press ⇒ key.
If the specification is not attained or is exceeded:
- Check idling speed stabilization => Page 6 , Final control diagnosis

=> Page 55 .
If no fault is found:
- Renew air mass meter => Page 19 , item 7 and perform idling check.

037906024D DIGIFANT 1.7 1390
Coding

1 2 3 4
Note:

Specification: 10...30 % at idle
- Press ⇒ key.

Golf 1992 , Vento 1992 ➤
If the specification is not attained or is exceeded:
- Check idling speed stabilization => Page 6 , Final control diagnosis

=> Page 55 .
If no fault is found:
- Renew air mass meter => Page 19 , item 7 and perform idling check.
1.16 - Checking control unit voltage supply
Note:
=> Page 2

Select function XX


037906024D DIGIFANT 1.7 1083
Coding
(From programme level number 1390 =>Seite 47 )

1 2 3 4
Note:

Specification: approx. battery voltage constant
- Press ⇒ key.
If the displayed figure fluctuates:

=> Page 9 , if necessary renew current supply relay (J176) with Ident. No. 30 (relay position 3).
1.15 - Checking air mass meter potentiometer 47

Golf 1992 , Vento 1992 ➤
037906024D DIGIFANT 1.7 1390

Coding

1 2 3 4
Note:

Specification: approx. battery voltage constant
- Press ⇒ key.
If the displayed figure fluctuates:

=> Page 9 , if necessary renew current supply relay (J176) with Ident. No. 30 (relay position 3).
1.17 - Checking fuel pressure regulator and holding pressure
The fuel pressure regulator controls the fuel pressure dependent upon intake manifold pressure.
• Fuel pump delivery rate OK, checking:
=> Rep. Gr. 20; Removing and installing parts of fuel system; checking fuel pump
Note:
To prevent fuel spray when loosening connections wrap a cloth around the connection.
- Connect pressure gauge V.A.G 1318:
Attention!
The pressure gauge cut-off tap must be closed (lever at 90 to throughflow direction -arrow-).

Golf 1992 , Vento 1992 ➤
▸07.93
- -> Pull fuel pipe -1- off connection -2- on cold start valve.
- Connect pressure gauge V.A.G 1318 with adapter 1318/10 to fuel pipe -1-.
08.93 ▸
- -> Remove plug -1- on fuel manifold and connect pressure gauge V.A.G 1318 with adapter V.A.G 1318/1
to fuel manifold.
- Start engine and run at idling speed.
- Check fuel pressure.
Specification: Approx. 2.5 bar
- -> Pull vacuum hose off fuel pressure regulator at junction piece -arrow-. The fuel pressure must rise to
approx. 3.0 bar.
- Check for leaks and holding pressure by watching pressure drop on gauge. After 10 minutes there must be
a residual pressure of
at least 2 bar.
If the holding pressure drops below 2 bar:

- After the pressure has built-up switch off ignition and at the same time clamp-off the return pipe -with blue
markings- on fuel manifold.
- Watch pressure drop on gauge.
If the pressure does not drop:
- Renew fuel pressure regulator.
If the pressure drops again:
- Check fuel pump non-return valve.
=> Rep. Gr. 20; Removing and installing parts of fuel system; checking fuel pump
1.17 - Checking fuel pressure regulator and holding pressure 49

Golf 1992 , Vento 1992 ➤
- Check pipe connections, O rings on fuel manifold and injectors for leaks.
- Check pressure gauge for leaks.
Note:
Before removing the pressure gauge, release fuel pressure by opening the cut-off tap. When doing this hold a
container over the connection.
1.18 - Checking cold start valve
▸07.93
Note:
The cold start valve injects only at coolant temperatures below 15 °C.
- -> Pull injector connector -1- off fuel manifold -2-.
Checking voltage supply
- -> Pull off plug of cold start valve (N17) and connect diode test lamp V.A.G 1527 with aux. cables from V.A.G
1594.

Golf 1992 , Vento 1992 ➤
- -> Pull connector off coolant temperature sender (G62).
- -> Set Digital potentiometer V.A.G 1630 -side A- to 3.8 kω
(corresp. approx. 10 °C) and connect to above connector using aux. cables from V.A.G 1594.
- Operate starter.
The LED must light up for approx. 1...4 seconds (Repeatedly starting engine reduces LED light up time).
- Set Digital potentiometer to 2.6 kω (corresponds to approx. 20 °C).
- Operate starter.
The LED must not light .
Otherwise:
- Reconnect to cold start valve connector.

=> Page 9 , if necessary renew Digifant control unit (J169).
Checking cold start valve (N17)
• Voltage supply OK.

• Cold start valve connector attached.
• Digital potentiometer connected to coolant temperature sender connector.
• Connector for injectors disconnected from fuel manifold.
- -> Set Digital potentiometer V.A.G 1630 -Side A- to 3,8 kω.
- -> Remove cold start valve and hold in a measuring container.

- Operate starter.
The cold start valve must spray uniformly for approx. 1...4
seconds.
- Dry off cold start valve nozzle.
The cold start valve must not drip for one minute or show signs of external dampness.
1.18 - Checking cold start valve 51

Golf 1992 , Vento 1992 ➤
1.19 - Removing and installing injectors
Removing
- Pull injector connector off fuel manifold.

- Remove intake hose and throttle valve housing.
- Pull return pipe off fuel manifold.
- To prevent fuel spray, cover pressurized fuel supply pipe with a cloth and pull off fuel manifold.
- Pull fuel pressure regulator vacuum hose off junction piece.
- ▸07.93: Pull hose off cold start valve.
Vehicles with automatic gearbox and without ABS
- Remove vacuum booster.
- Remove fuel manifold securing screws.
Note:
The ratchet and socket SW5, with 1/4' drive, are particularly suitable for removing the socket head screws.
- Pull fuel manifold with injectors out left, facing direction of travel.
- -> Remove screw -1- and lever upper part of fuel manifold -2- of fuel manifold -3- at point indicated by arrows.
- -> Clamp threaded end of socket head screw (M6) in a vice and press out injectors.
Installing
Note:
Renew injector damaged seals/gaskets and O-rings.
- Place gasket on fuel manifold upper part.

Golf 1992 , Vento 1992 ➤
- -> Insert injectors into fuel manifold upper part and moisten O-rings -arrows- with oil.
- Press fuel manifold upper part with injectors into the fuel manifold.
- -> Tighten screw -1- to 10 Nm.

- Place fuel manifold on intake manifold and tighten securing screws to 10 Nm.
- Connect fuel pressure regulator vacuum hose to junction piece.
- Connect fuel supply and return hoses to cold start valve (if fitted) and attach connector for injectors.
- Install vacuum booster (if fitted), throttle valve housing and intake hose.
1.20 - Checking injectors
• Hall OK., checking => Page 68 .
- ▸07.93: Pull plug off cold start valve.

- -> Pull connector -1- fror injectors off fuel manifold -2-.
- -> Check voltage supply for all injectors. To do this, connect diode test lamp V.A.G 1527 with aux. cables
from V.A.G 1594 to plug -1-.
- Operate starter.
1.19 - Removing and installing injectors 53

Golf 1992 , Vento 1992 ➤
The LED must flicker
LED permanently lid:
- Renew earth strap from battery to gearbox.

- Renew Digifant control unit (J169).
LED does not light up or flicker:
- Attach connector for injectors.

- Carry out electrical check, test step 7=>Page 9 , if necessary renew Digifant control unit (J169).
Checking resistance
- -> Check resistance on connection -2- for all injectors using hand multimeter V.A.G 1526 and aux. cables
from V.A.G 1594.
Specification: 3.7...5.0 ω(all 4 injectors OK.)
If the specification is not attained:
- Remove fuel manifold with injectors => Page 52 , removing and installing injectors.
- -> Remove bolt -1- and lever fuel manifold upper part -2- of fuel manifold - 3 - as indicated by arrows.
- Repeat check on individual injectors, if necessary renew injector(s).
Specification: 15...20 ω
Checking spray pattern and for leaks
• ▸07.93: Cold start valve connector pulled off.
- Remove fuel manifold with injectors => Page 52 .

Golf 1992 , Vento 1992 ➤
- Connect supply and return pipes to fuel manifold, using extension hoses if necessary.
- ▸07.93: Reconnect cold start valve hose.
- -> Place injectors in the measuring appliance V.A.G 1602.
- Attach connector -2- to fuel manifold connection -1-.
- -> Pull 2-pin plug off coolant temperature sender (G62).
- Pull plug off ignition transformer.
- Operate starter. The injectors must spray uniformly.
- Switch off ignition and check injectors for leaks. No more than
2 drops/min
may leak from each injector.
Note:
When installing the injectors ensure that the O rings
are not damaged.
1.21 - Checking intake air system for leaks (unmetered air)
Checking with engine leak detector spray G 001 800 A1
Notes:
◆ The vacuum in the intake system will cause the leak detector spray to be drawn in with the outside air. The
leak detector spray reduces the ignitability of the mixture. This leads to a drop in engine speed and to a
significant increase of the CO content.
◆ The safety precautions listed on the container must be adhered to.
- -> Connect CO tester V.A.G 1363A with adapter V.A.G 1363/3 to CO sampling pipe.
- Systematically spray parts of the intake system with engine leak detector spray.
1.20 - Checking injectors 55

Golf 1992 , Vento 1992 ➤
If the engine speed drops and the CO content changes:
- Check for leaks in the area of intake system sprayed and eliminate leak.
1.22 - Checking intake air preheating
Checking regulating flap
• Regulating flap vacuum unit not leaking
- Loosen air cleaner upper part and remove filter element.

- -> Position air cleaner upper part so that the regulating flap in air cleaner lower part can be seen.
- Pull vacuum pipe to vacuum unit -1- off temperature regulator -3-.
- Connect vacuum pipe to hand vacuum pump V.A.G 1390.
- Operate pump and check ease of movement of the regulating flap and function of the vacuum unit.
Regulating flap must close off the cold air
intake -4-
Checking temperature regulator
- Connect vacuum pipe to temperature regulator.

- -> Check position of regulating flap after max. 20 seconds.
Temperature of tempera‐ Regulating flap position

ture regulator
Below 20 °C Cold air inlet -4- closed
Above 30 °C Warm air inlet -2- closed
Between 20 and 30 °C Between cold and warm
air inlet

Golf 1992 , Vento 1992 ➤
1.23 - Basic throttle valve setting
Note:
The limiting screw is set in the factory and must not be altered. However, if the screw is turned inadvertently
set again as follows.
- -> Turn limiting screw -arrow- out until a gap exists between stop lever -1- and limiting screw -arrow-.
- Turn limiting screw in, until it just touches the lever -1-.
Note:
To determine the exact point of contact, place a thin piece of paper between lever -1- and limiting screw. By
continually moving the paper to and fro, and at the same time turning the limiting screw in, the exact point of
contact can be determined.
- From this point, turn screw in a further 1/2 turn.

- Check throttle valve potentiometer => Page 40 .
- Carry out idling check => Page 33 .
1.23 - Basic throttle valve setting 57

Golf 1992 , Vento 1992 ➤
1.24 - Vacuum hose connection diagram
Manual gearbox
1 Intake manifold
2 For air conditioning system
3 To brake servo
◆ Connect vacuum unit hose to hose connection which is made of metal or with groove.

Golf 1992 , Vento 1992 ➤
7 Vacuum unit
9 From activated charcoal filter
10 Junction piece
1.24 - Vacuum hose connection diagram 59

Golf 1992 , Vento 1992 ➤
Automatic gearbox
1 Intake manifold
3 To brake servo
5 Vacuum booster
6 To intake hose
◆ Connect vacuum unit hose to hose connection made of metal or with groove

Golf 1992 , Vento 1992 ➤
9 Vacuum unit
11 From activated charcoal filter
12 Junction piece
1.24 - Vacuum hose connection diagram 61

Golf 1992 , Vento 1992 ➤
28 - Ignition system
1 - Digifant injection and ignition system

1.1 - Digifant injection and ignition system
1.2 - Servicing ignition part
Notes:
◆ Only the components which specifically relate to the ignition system are dealt with here. For the other com‐
ponents of the injection and ignition system => Repair group 24.
◆ Electrical check of Digifant injection and ignition system => Page 9
◆ The injection and ignition system control unit is equipped with self diagnosis.
◆ Components marked with a * are checked via the self diagnosis.
◆ Before carrying out repairs and for fault finding, interrogate the fault memory.
=> Page 3 , interrogating and erasing fault memory
Safety precautions => Page 65
Checking and adjustment data, spark plugs => Page 66
62 28 - Ignition system
Golf 1992 , Vento 1992 ➤
1 HT cable
◆ Check for continuity
2 Suppressor
◆ 0.6...1.4 kω
3 Terminal 1
4 Terminal 15
5 Ignition transformer output stage (N157)
6 10 Nm
7 Ignition transformer (N152)
8 Connector
9 Earth strap
10 Knock sensor 1 (G61)*
◆ On engine block
1.2 - Servicing ignition part 63

Golf 1992 , Vento 1992 ➤
11 20 Nm
◆ Tightening torque influences the function of the knock sensor
12 Spark plug connector
◆ 4...6 kω
13 Spark plug, 30 Nm
◆ Type and electrode gap
=> Page 66
14 20 Nm
15 Clamp
16 O ring
17 Distributor with Hall sender (G40)
◆ Installing => Page 66
◆ Checking and adjusting ignition timing => Page 33 , idling check
◆ Checking Hall sender
=> Page 68
Golf 1992 , Vento 1992 ➤
18 Dust cap
19 Rotor arm
◆ Marking: R1
◆ 0.6...1.4 kω
20 Distributor cap
◆ Check for cracks and signs of tracking
◆ Check contact wear
◆ Clean before fitting
◆ Check carbon brush for wear and freedom of movement
21 Screening cap
1.3 - Safety precautions

To prevent injuries to persons and/or damage to the injection and ignition system, the following must be ob‐
served:
◆ Do not touch or pull off ignition wiring when engine is running or turning at starter speed.
◆ The ignition must be switched off when disconnecting or connecting injection and ignition system wiring as
well as test instrument cables.
◆ If the engine is to be turned at starter speed, without starting, e.g. when checking compressions, pull plug
off Hall sender (distributor).
◆ Do not connect a capacitor to terminal 1 (-).
1.2 - Servicing ignition part 65

Golf 1992 , Vento 1992 ➤
◆ Do not replace 1 kω (identification: R1) with a different type even for radio interference suppression.
◆ For suppression purposes only 1 kω resistances are to be used on the H.T. leads and 5 kω spark plug
connectors.
1.4 - Test data, spark plugs
Engine code 2E
Ignition timing1)
Checking and adjusting => Page 33 ,
Idling check
Ignition timing 1-3-4-2
Spark plugs1)
VW/Audi 101 000 026 AB
101 000 038 AA
Manufacturer's designation N7 BMC
14G-8 DTU
Electrode gap 0.7...0.9 mm
Tightening torque 25 Nm
1.5 - Installing distributor
- -> Set flywheel -A- or drive plate -B- to TDC No. 1 cylinder.
Engine removed
Golf 1992 , Vento 1992 ➤
- -> Set vibration damper (V-belt pulley) to TDC No. 1 cylinder.
- -> Mark on camshaft sprocket must align with arrow on cylinder head.
- -> Align oil pump shaft drive tongue with threaded hole.
- -> Insert distributor so that the rotor arm points to No. 1 cylinder mark on the distributor body.
- Before fitting, clean distributor cap and check for cracks and signs of tracking, renew if necessary.
- Checking and adjusting ignition timing =>Page 33 , checking idling speed.
1.6 - Checking ignition timing control

• No fault stored in fault memory
• Engine oil temperature at least 80 °C
1.5 - Installing distributor 67

Golf 1992 , Vento 1992 ➤
• Ignition timing OK., =>Page 33 , checking idling speed
- Set ignition tester to 2800 rpm.
- Slowly increase speed to slightly above 2800 rpm until the ignition timing (advance angle) is indicated.
Specification: 35...45 ° before TDC
If the ignition timing does not advance:
- Carry out electrical check => Page 9 , if necessary renew control unit (J169).
1.7 - Checking Hall sender

- Carry out electrical check, test step 14 => Page 9 (test box remains connected for further checks).
- Connect Hall sender connector on distributor.
- -> Bridge test box -2- sockets 1 + 35 with short cable -4- (V.A.G 1598/18-1).
- Bridge test box -2- sockets 4 + 45 with cable -1- (V.A.G 1594/22).
Note:
If the measuring cable -1- (V.A.G 1594/22) is equipped with one plug and two sockets, connect plug to socket
4 of test box and one socket to cable V.A.G 1594/19 and long measuring cable V.A.G 1598/18-1 to socket 45
of test box.
- Connect diode test lamp V.A.G 1527 with connector -3- (V.A.G 1594/15) and long cable -4- (V.A.G
1598/18-1) to sockets 44 + 45.
- Operate starter.
LED must flicker
The LED does not flicker:
Golf 1992 , Vento 1992 ➤
- Renew distributor with Hall sender

=>Page 64 , Item 17 .
- Connect connector to Digifant control unit.

- Pull plug off Hall sender (distributor).
- -> Connect hand multimeter V.A.G 1526 to measure voltage with aux. cables from V.A.G 1594 to the outer
contacts of the plug.
Specification: At least 10 V
If no voltage is present:
1.8 - Checking ignition transformer

- Pull connector and H.T. cable off ignition transformer (N152).
- -> Check primary resistance with hand multimeter V.A.G 1526 between terminals 1 and 15.
Specification: 0.5...0.7 ω
- Check secondary resistance with hand multimeter between terminals 4 and 15.
Specification: 3...4 kω
If the specifications are not attained:
- Remove ignition transformer and unscrew the ignition transformer output stage (N157) => Page 63 .
- Repeat check.
1.7 - Checking Hall sender 69

Golf 1992 , Vento 1992 ➤
1.9 - Checking ignition transformer output stage

• Hall sender OK.
• Electrical check, Test step 2 OK, checking

=>Page 9
• Ignition transformer OK.
- Pull 3 pin plug off ignition transformer.

- -> Connect hand multimeter V.A.G 1526 to measure voltage with aux. cables from V.A.G 1594 to the con‐
tacts 1 and 3 of the disconnected plug.
Specification: Approx. battery voltage
- Switch off ignition.
Checking activation
- Pull off connector for injectors and cold start valve (if fitted).
- -> Connect diode test lamp V.A.G 1527 with aux. cables from V.A.G 1594 and adapters V.A.G 1594/15 to
contacts 2 and 3 of the plug.
- Operate starter and check ignition signal from Digifant control unit.
LED must flicker
The LED does not flicker:

Golf 1992 , Vento 1992 ➤
LED flickers:
- Switch off ignition.

- Connect 3 pin plug and H.T. cable to ignition transformer.
- -> Connect diode test lamp with aux. cables and clamps to the contacts 1 and 15 on ignition transformer.
Warning!
During the following test do not touch the terminals of the ignition transformer or test cables.
LED must light up for
1...2 seconds
- Operate starter.
The LED must flicker,
if necessary renew output stage.
1.9 - Checking ignition transformer output stage 71

VW Golf 3 2e Digifant Injection Ignition Eng

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VW Golf 3 2e Digifant Injection Ignition Eng

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Service

Golf 1992 , Vento 1992 ➤

Service Department. Technical Information

01 - Self diagnosis, Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

01 - Self diagnosis, Electrical check

1.3 - Technical data of self diagnosis

Function Ignition switched Engine idling

Volkswagen Technical Site: http://vwts.ru http://vwts.info

1.1 - Self diagnosis 1

• Battery voltage OK.

- Connecting fault reader:

-> Indicated on display:

2 01 - Self diagnosis, Electrical check

-> Indicated on display:

- Further measures see repair procedures.

1.5 - Interrogating and erasing fault memory

Only when engine does not start:

- Switch on printer with the Print button

-> Indicated on display:

- Input 02 for "Interrogate fault memory" function and confirm with Q.

-> Indicated on display:

- Input 06 for "End output" function and confirm with Q.

If one or more faults are stored:

-> The number of faults stored will be shown on the display.

- Input 06 for "End output" function and confirm with Q.

-> Indicated on display:

- Input 02 for "Interrogate fault memory" function and confirm with Q.

-> Indicated on display:

- Input 05 for "Erase fault memory" function and confirm with Q.

-> Indicated on display:

-> Indicated on display:

- Input 06 for "End output" function and confirm with Q.

1.6 - Fault table

4 01 - Self diagnosis, Electrical check

V.A.G 1551 print-out Possible fault cause Fault elimination

V.A.G 1551 print-out Possible fault cause Fault elimination

1.6 - Fault table 5

V.A.G 1551 print-out Possible fault cause Fault elimination

1.7 - Final control diagnosis

Note for Model Year 1992 (N):

1. Fuel pump relay (J17)

2. Idling speed stabilisation valve (N71)

3. Activated charcoal filter solenoid valve 1 (N80)

-> Indicated on display:

-> Indicated on display:

Actuate fuel pump relay (J17):

- Confirm input with Q button.

-> Indicated on display:

6 01 - Self diagnosis, Electrical check

If the relay does not click:

- Check fuel pump relay:

Activate idling stabilization valve (N71):

-> Indicated on display:

The idling stabilization valve must click.

If the idling stabilization valve does not click:

LED flashes or lights up:

- Renew idling stabilization valve.

LED does not flash or light up:

- Carry out electrical check, Test step 14

Activate solenoid valve 1 for activated charcoal filter (N80):

-> Indicated on display: