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					  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  25 Continuous Injection System (CIS) (Page GR-25)


Continuous Injection System
  CIS ECM
  Intake air system
  Component layout
  Throttle body
  Technical data
  Ignition timing, idle, co
  Oxy. sensor, checking
  Accel./decel fuel shut-off
  Speedometer speed signal, checking
  Coolant temperature sensor, checking
  Cold start valve, checking
  Air flow sensor, checking and adjusting
  Air flow sensor potentiometer, checking and adjusting
  Fuel pressure, checking
  Injection quantity comparative measurement
  Idle and full throttle switches, checking and adjusting
  Intake air preheating, checking
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
CIS-E-Motronic system, component locations (Page 25-10-1)




 1 - Harness connector for Oxygen sensor (G 39)
       up to 7-90, as shown
       after 8-90, 4-pin harness connector for Oxygen sensor (G 39)* and Oxygen sensor
       heater (Z 19)
       mounted on right engine mount
 2 - Throttle body
     Types: vehicles with separate idle switch (F 60)* and full throttle switch (F 81)*
            vehicles with integrated idle switch (F 60)*, full throttle switch (F 81)* and throttle
            potentiometer
 3 - CIS-E Motronic control unit (J 204)*
 4 - Intake air temperature sensor (G 72)
 5 - EGR valve (exhaust gas recirculation)
      California only
      only function: monitoring the EGR system
 6 - CO tap tube
 7 - Idle stabilizer valve (N 71)**
 8 - Ignition coil power output stage (N 70)
     checking, see Repair Group 28
 9 - Ignition coil (N)
     checking, see Repair Group 28
10 - 6-pin harness connector
11 - Ignition distributor
     with Hall sender (G 40)*
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  CIS-E-Motronic system, component locations (Page 25-10-2)


  12 - Vacuum amplifier
       for EGR system (California)
  13 - Ignition timing sender (G 4)*
          on cylinder number 4 ignition wire
          installed position: tabs must point toward ignition distributor
  14 - Thermopneumatic valve
         on coolant pipe
         for EGR system (California)
  15 - Coolant temperature sensor (G 62)*
       for CIS-E Motronic system
  16 - Cold start valve (N 17)**
  17 - Knock sensor I (G 61)*
  18 - Fuel injector(s)
  19 - Knock sensor II (G 66)*
  20 - Control flap for intake air pre-heating
  21 - Differential pressure regulator (N 73)**
  22 - Fuel distributor
  23 - Carbon canister
       carbon canister system repairing, see Repair Group 20
  24 - Air filter
  25 - Air flow sensor potentiometer (G 19)*
  26 - Fuel pressure regulator
  27 - Air flow sensor
  28 - Solenoid valve I (N 80)**
       Solenoid valve II (N 115)
       for carbon canister, see Repair Group 20
  29 - Spark plug(s)
         25 NM (18 ft lb)
         specifications and types, see Repair Group 28
   30 - Harness connector for idle switch (F60)* and full throttle switch (F 81)*
* checked using self-diagnosis, see Repair Group D2
** checked using output checks, see Repair Group D2
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
Fuel injection system, repairing (Page 25-20-1)




A - Section 25-50
B - Section 25-50
C - Section 25-50
1 - 10 Nm (7 ft lb)
2 - 20 Nm (15 ft lb)
3 - Fuel return line
      blue
      to pump reservoir, see Repair Group 20
 4 - Fuel supply line
       black
       from pressure reservoir, see Repair Group 20
 5 - Bracket
     mounted on air flow sensor, see section 25-40 item 8
 6 - 3.5 Nm (31 in. lb)
 7 - Pressure regulator
     system, differential and residual pressure checking, see section 25-190
 8 - Differential pressure regulator harness connector
     gray
10 - Pressure regulator (N 73)**
       differential pressure checking, see section 25-190
       resistance: 15 to 25 Ohms
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Fuel injection system, repairing (Page 25-20-2)


  11 - O-ring
       always replace
  12 - Control plunger
         sensor plate lever and control plunger checking, see section 25-170
         control plunger removing and installing, see section 25-170
  13 - Sealing ring
         smaller diameter toward control plunger
         seals sensor plate only when in rest position
  14 - Stop screw for control plunger
       free play adjustment at fuel distributor, see section 25-170
  15 - 20 Nm (15 ft lb)
       if there are engine running disturbances, replace mini-filter with banjo bolt
  16 - Fuel distributor
         injection quantity comparative measurement checking, see section 25-200
         after installing fuel distributor, check sensor plate free play and adjust if necessary, see
         section 25-170
   17 - Cap screw
          10 Nm (7 ft lb)
          connection for pressure measuring gauge
**checked using output checks, see Repair Group D2
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
CIS-E Motronic control unit, component layout (Page 25-30-1)




 1 - Ground connection
     fastened to Oxygen sensor harness connector bracket
 2 - Harness connector for Oxygen sensor (G 39) and sensor heater (Z 19)
       starting 8-90, 4-pin harness connector mounted on right engine mount
       check voltage supply for Oxygen sensor heater with engine running, between terminals
       1 (brown) and 2 (red/white): must be approx. battery voltage
       check Oxygen sensor heater for continuity via OXS harness connector (white wires)
 3 - Oxygen sensor (G 39) harness connector
       up to 7-90, single pin harness connector mounted on right firewall
 4 - Oxygen sensor heater (Z 19) harness connector
       up to 7-90, 2-pin harness connector mounted on right firewall
       check voltage supply for Oxygen sensor heater with engine running, must be approx.
       battery voltage
       check Oxygen sensor heater for continuity via OXS harness connector (white wires)
 5 - Harness connector
       only disconnect or connect harness connector with ignition switched off
       to disconnect, release holding spring from CIS-E Motronic control unit
       CIS-E Motronic system electrical checking, see Repair Group D2
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  CIS-E Motronic control unit, component layout (Page 25-30-2)


   6 - CIS-E Motronic control unit (J 204)*
         for fuel injection, Oxygen sensor control, ignition map, knock regulation and output
         checks
         with Fault memory
         for output checks and self-diagnosis, see Repair Group D2
   7 - Mounting plate
   8 - 10 Nm (7 ft lb)
   9 - A/C harness connector
       in right side of plenum
  10 - Oxygen sensor (G 39)*
         50 Nm (37 ft lb)
         installation location: catalytic converter
         coat threads with G5 but do not allow compound to enter sensor body slots
         checking see section 25-100
*check using self-diagnosis, see Repair Group D2
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
Intake air system, component layout (Page 25-40-1)




C - Section 25-20
D - Section 25-50
E - Section 25-50
F - Section 25-50
1 - From carbon canister
    carbon canister system, repairing, see Repair Group 20
 2 - Harness connector
     gray
 3 - Carbon canister solenoid valve I (N 80)**
       gray
       resistance 30 to 60 Ohms
 4 - Carbon canister solenoid valve II (N 115)
       black
       checking, see Repair Group 20
 5 - Harness connector
     black
 6 - 3.5 Nm (31 in. lb)
 7 - Mounting bracket
 8 - Mounting bracket
     for fuel pressure regulator, see section 25-20 item 5
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
Intake air system, component layout (Page 25-40-2)


 9 - Air flow sensor
        sensor plate lever and control plunger checking, see section 25-170
        sensor plate rest position and free play, checking and adjusting, see section 25-170
        air flow sensor potentiometer (G 19)*; checking, see section 25-180
10 - Gasket
     always replace
11 - Warm air intake
     hose to heat shield from exhaust manifold
12 - Adaptor tube
13 - Control flap
       intake air pre-heating checking, see section 25-220
       not available as an individual part
14 - Air filter housing lower section
15 - Cold air intake
16 - Air filter element
17 - Air filter housing upper section
18 - Harness connector
     white
19 - CO adjustment plug
       CO adjusting screw underneath
       CO content and idle speed checking and adjusting, see section 25-90
20 - Intake air boot
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
Fuel injection components, layout (Page 25-50-1)




A - See section 25-20
B - See section 25-20
D - See section 25-40
E - See section 25-40
F - See section 25-40
1 - Connecting tube
2 - Temperature controller
      intake air pre-heating checking, see section 25-220
      installation position: brass connector nipple with notch toward control flap see section
      25-40 item 13
 3 - Intake air boot
 4 - Throttle body assembly
        with idle* and full throttle* switch
        disassembling and reassembling, see section 25-60
 5 - 20 Nm
 6 - Gasket
     always replace
 7 - Intake manifold upper section
     first fasten to lower section then mount on rear brackets
 8 - Bracket
     for fuel injector lines and ignition wiring guide
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
Fuel injection components, layout (Page 25-50-2)


 9 - CO tap tube
     CO content and idle speed checking and adjusting, see section 25-90
10 - Cap
     if removed; ensure that re-installation is tight
11 - Check valve
       for vehicles without ABS only
       note installed position: arrow on valve points toward intake manifold
12 - From multifunction indicator (A/C)
       for vehicles without ABS only
       vacuum connections, see section 25-230
13 - From brake booster
     for vehicles without ABS only
15 - Ground connection
16 - Harness connector
     white
17 - Coolant temperature sensor (G 62)*
       for CIS-E Motronic system
       checking, see section 25-150
       for sensor resistance see chart in Technical data section 25-70
18 - Harness connector
     gray
19 - Idle stabilizer valve (N 17)**
     resistance 4 to 12 Ohms
20 - 10 Nm (7 ft lb)
21 - Cold start valve (N 17)**
       injection pattern, injection time and leak testing, see section 25-160
       resistance 8 to 13 Ohms
22 - Harness connector
     blue
23 - Hose connector
24 - Calibrated insert
     red
25 - From crankcase breather ventilation housing
26 - Fuel injector insert
       install upper part with D6 locking compound
       20 Nm (15 ft lb)
       remove and install using 3135
27 - O-rings
       always replace
       moisten with fuel before installing
28 - Fuel Injector(s)
       air shrouded
       injection quantity comparative measurement checking, see section 25-200
       check pressure using VAG 1349 injector tester; must be 3.7 to 4.8 bar
29 - Calibrated insert
     blue
30 - Intake manifold lower section
31 - Locking clip
     *checked using self-diagnosis, see Repair Group D2
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
Throttle body, disassembling and reassembling (Page 25-60-1)




 1 - Throttle body
     if stop screw blocked, replace throttle body
 2 - Gasket
     always replace
 3 - Full throttle switch (F 81)*
       checking and adjusting, see section 25-210
       for vehicles built after 10-90 starting with control unit:
       49 States: 8A0 907 404
       California: 893 907 404Q
       full throttle switch functional testing, see section 25-210
 4 - Harness connector
     to CIS-E Motronic control unit (J 204)*
 5 - Harness connector
       for vehicles with automatic transmission only
       to automatic transmission control unit
 6 - Throttle body
       idle* and full throttle* switches are contained in an assembly with the throttle
       potentiometer
       if stop screw is blocked; replace throttle body
 7 - Heat shield
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Throttle body, disassembling and reassembling (Page 25-60-2)


    8 - Throttle potentiometer
          with integrated idle switch (F 60)* and full throttle switch (F 81)*
          checking and adjusting, see section 25-210
          vehicles built starting 10-90 starting with control unit:
          49 States: 8A0 907 404
          California: 893 907 404Q
    9 - Screw
          must be turned in all the way
          idle speed CANNOT be adjusted
  10 - Idle switch (F 60)*
          checking and adjusting, see section 25-210
          for vehicles built after 10-90 starting with control unit:
          49 States: 8A0 907 404
          California: 893 907 404Q
*checked by self-diagnosis - Repair Group D2
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Technical Data (Page 25-70-1)


Engine code                                                                                      9A
CIS-E Motronic control unit RPM cut-off                           to 9-90               approx. 6800 RPM

Fuel shut off by control current reversal at pressure regulator   after 10-90           approx. 7000 RPM

Ignition timing
Checking value                                                                             4-8   BTDC
See Repair Group 28 for additional information

speed*
Checking value                                                    to 9-90                 700-900 RPM
CANNOT be adjusted; controlled by idle stabilization system       after 10-90            800-1000 RPM

CO content*
Checking value                                                                         0.2 to 1.2 volume %
Measured at CO tap tube

Adjusting value (via pressure regulator control current adjustment)             2.5     2.5 mA (must fluctuate)

*Note checking/adjusting conditions section 25-90

Fuel pressure
System pressure                                                                             6.1-6.6 bar

Differential pressure
Differential pressure regulator harness connector disconnected                         approx. 0.3 to 0.5 bar
                                                                                      below system pressure
Differential pressure regulator for harness connector connected                        approx. 1.3 to 1.6 bar
                                                                                      below system pressure
Residual pressure
After minimum of 10 minutes                                                                   3.3 bar
After minimum of 20 minutes                                                                   3.2 bar

Fuel injectors
Spray pressure                                                                            3.7 to 4.8 bar

Injection quantity tolerance within a set:                                               2.0 ml maximum
Idle measurement (1st detent) with a 20 ml accumulation

Full throttle measurement (2nd detent) with 80 ml accumulation                           8.0 ml maximum

Idle stabilizer valve resistance                                                          4 to 12 Ohms

Pressure regulator resistance                                                             15 to 25 Ohms

Cold start valve resistance                                                               8 to 13 Ohms
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Technical Data (Page 25-70-2)


Engine code                                                                               9A

Idle switch, switching point
Using feeler gauge; measure gap between activating lever and throttle lever   0.15 to 0.50 mm before full
or between throttle lever and idle stop                                               throttle stop

Full load switch, switching point                                             10   2   before full throttle
Measured using 3084 protractor and adaptor 3084/1                                        stop


Coolant temperature sensor (G 62) resistance




Note
Resistance is dependent on coolant temperature.
  If resistance measurement is acceptable but Repair Group D2 is still displayed via
  self-diagnosis, it is possible that there is an intermittent signal. If this is the case,
  perform Electrical Test step 23 in Repair Group D2.
  For vehicles build after 10-90 starting with control unit:
  49 States: 8A0 907 404
  California: 893 907 404Q
  The sensor can also be checked using the VAG 1551 Diagnostic Tester, see section
  25-150.
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Safety precautions (Page 25-80-1)


Rules of Cleanliness
CAUTION!
When working on the fuel supply/injection system, carefully observe the following rules:
 1 - thoroughly clean connection and surrounding areas before loosening
     connection
 2 - after removing components, place in clean area and cover with foil or paper,
     avoid using rags
 3 - components which have been opened or disassembled must be carefully
     covered or sealed if repair cannot be carried out immediately
 4 - install clean parts only
        remove replacement parts from package just before installing
        do NOT use spare parts that were stored loose or unpackaged (e.g. in tool
        boxes, etc.)
 5 - when fuel system is open:
        avoid using compressed air whenever possible
        avoid moving the vehicle whenever possible
Safety measures
WARNING!
Fire Hazard! Do not smoke or have anything in area that can ignite fuel.
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Safety precautions (Page 25-80-2)


CAUTION!
Observe the following precautions to prevent personal injury as well as possible damage
to sensitive electrical components.
     switch OFF the ignition before connecting or disconnecting components or
     test equipment
     connect and disconnect battery ONLY with ignition switched OFF otherwise
     the control unit could be damaged
     if the engine must be cranked but not started (for compression testing etc.)
     disconnect Hall sender harness connector at ignition distributor
Note
A variety of electrical connectors are used on this vehicle, ALWAYS use the VW 1594 adaptor kit
to connect test instruments to these connectors.
CAUTION!
Before disconnecting a customers battery; ALWAYS ask for the radio code (if equipped
with an anti-theft radio).
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Ignition timing, idle speed and CO content, checking/adjusting (Page 25-90-1)


Checking conditions:
     engine coolant temperature 80 C (176 F) minimum
     all electrical consumers switched OFF
     radiator cooling fan must not be running while taking measurements
     A/C switched OFF
     Fault memory must be clear of stored faults, if any are found they must be corrected
     and then Fault memory erased before proceeding
     no pressure measuring equipment connected
     if injector lines were loosened or replaced, run engine up to 3000 RPM several times
     and then allow to idle for at least 2 minutes before performing the adjustment any
     adjustments
     exhaust must be leak-free
     throttle cable adjustment OK, see Repair Group 20
Vehicles with automatic transmission:
  set selector lever in P or N position
Vehicles built up to 9-90:
  switch OFF ignition




  connect VAG 1367 engine tester using VAG 1367/8 inductive pickup
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Ignition timing, idle speed and CO content, checking/adjusting (Page 25-90-2)




  connect Sun EPA 75 (or EPA approved equivalent) CO tester using VAG 1363/3
  adaptor connected to CO tap tube
CAUTION!
Adaptor must be connected tightly to CO tap tube to prevent measuring errors.
    start engine and let idle
    check ignition timing
       checking value 4 to 8 BTDC
If adjustment is necessary see Repair Group 28 for additional information
    check idle speed (CANNOT be adjusted)
       must be 700 to 900 RPM
Note
If RPM is held at a constant 700 RPM, perform Electrical Test Steps 5 and/or 6 in Repair Group
D2.
   check CO content
     must be 0.2 to 1.2 volume %
If NO, adjust CO as follows:
   switch OFF ignition




  disconnect harness connector 1 from carbon canister solenoid valve 2 (black)
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
Ignition timing, idle speed and CO content, checking/adjusting (Page 25-90-3)




disconnect crankcase housing breather hoses 1 and 2 from breather housing 3 and
place hoses such that only fresh air can be drawn in
   calibrated insert 4 must remain in hose 2
ensure that ignition is switched OFF
disconnect harness connector from differential pressure regulator 1
connect test adaptor VAG 1315A/1 between differential pressure regulator and
harness connector (arrows)
switch Fluke 83 multimeter to 200 mA range




connect multimeter to test adaptor VAG 1315A/1 using jumper wires from VW 1594
adaptor kit
switch ON ignition
  control current must be displayed as positive polarity (90-110 mA)
If negative polarity is displayed
    reverse multimeter test leads
    start engine and let idle




    adjust control current using CO adjusting screw 2
       setting value: 2.5 2.5 mA (fluctuating)
If control current does NOT fluctuate
    check Oxygen sensor (G 39) and Oxygen sensor control, see section 25-100
During adjustment:
       do not press down on adjusting wrench
       do not accelerate engine with wrench inserted in adjustment screw
After each adjustment:
    remove adjusting wrench and briefly operate throttle before reading control current
    read and then erase Fault memory see Self-diagnosis, Repair Group D2
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Ignition timing, idle speed and CO content, checking/adjusting (Page 25-90-4)


The following procedure applies to vehicles built after 10-90 starting with control unit:
49 States: 8A0 907 404
California: 893 907 404 Q
  switch OFF ignition
  connect VAG 1551 Diagnostic Tester, see Repair Group D2 for additional
  information




  connect VAG 1367 engine tester using VAG 1367/8 inductive pickup




  connect Sun EPA 75 CO tester (or EPA approved equivalent) using VAG 1363/3
  adaptor on CO tap tube
Note
Adaptor must be connected tightly to CO tap tube to prevent measuring errors.
  start engine and let idle
  press 1 button to select "rapid data transfer" mode
  press 0 and 1 buttons to select "engine electronics"
  press Q button to enter input
  press      button
  press 0 and 4 buttons to select "initiate basic adjustment" function
  press Q button to enter input
     display will appear as shown

Initiate basic adjustment       HELP
Input display group number XX
  press 0 button twice to display group 00
     display will appear as shown

Initiate basic adjustment        Q
Input display group number 00


  press Q button to enter input
     display will appear as shown
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Ignition timing, idle speed and CO content, checking/adjusting (Page 25-90-5)



Initiate basic adjustment            Q
Input display group number          00


  press Q button to enter input
     display will appear as shown

System in basic adjustment
1 2 3 4 5 6 7 8              9


Note
       the display channel values are in decimal form
       2000 is the maximum number of RPM's that can be displayed at this setting
       when this function is selected, the DLS (digital idle stabilizer) is switched off and the
       carbon canister solenoid valve I is activated
    observe channel 9 of display
       display value must be 5
lf value other than 5 is displayed
    read measurement block, see Repair Group D2
    check ignition timing
       checking value: 4 to 8 BTDC
If NO
    adjust ignition timing, see Repair Group 28 for additional information
    check idle speed RPM's (can NOT be adjusted)
       must be 800 to 1000 RPM
    observe CO content
       must be 0.2 to 1.2 volume %
If YES
    press      button
    press 0 and 6 buttons to select function "end output"
    press Q button to enter input
If CO content not within specs
    adjust CO content as follows
    switch off ignition
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
Ignition timing, idle speed and CO content, checking/adjusting (Page 25-90-6)




disconnect hoses 1 and 2 from breather housing 3
   locate such that only fresh air can be drawn in
   ensure that connector piece 4 (with opening) remains in hose 2
switch Fluke 83 multimeter to mA range
disconnect differential pressure regulator (N 71) harness connector




connect test adaptor VAG 1315A/1 between regulator and harness connector
(arrows)
connect multimeter to test adaptor VAG 1315A/1 using jumper leads from VW 1594
adaptor kit
switch ignition on
   control current polarity (90-110 mA) must be positive (+); if not, swap test
   connections
start engine and let idle
return system to "basic setting", see Repair Group D2
  adjust control current using CO adjusting screw 2
     adjusting value: 2.5 2.5 mA (must fluctuate)
If NO
   check Oxygen sensor (G 39) and Oxygen sensor control, Section 25-100
CAUTION!
During adjustment;
     do not push down on wrench while adjusting
     do not accelerate engine while wrench is inserted in adjusting screw
     remove wrench after each adjustment and briefly raise engine speed before
     reading multimeter
  read and then erase Fault memory, see Repair Group D2
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Oxygen sensor and Oxygen sensor control, checking (Page 25-100-1)


Requirements
    engine coolant temperature 80 C (176 F) minimum
    idle adjustment OK
    no leaks in exhaust system between catalyst and cylinder head
    voltage supply for Oxygen sensor heater OK
  switch ignition OFF
For vehicles built up to 9-90:
  switch Fluke 83 multimeter to mA range
  disconnect differential pressure regulator (N 71) harness connector




  connect test adaptor VAG 1315A/1 between regulator and harness connector
  (arrows)
  connect multimeter to test adaptor VAG 1315A/1 using jumper leads from VW 1594
  adaptor kit
  switch ignition ON
     control current polarity (90-110 mA) must be positive (+); if not, swap test
     connections
  start engine and let idle for 2 minutes minimum
  record control current




  clamp crankcase housing breather hose 1
     control current must decrease
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Oxygen sensor and Oxygen sensor control, checking (Page 25-100-2)




if NO
For vehicles built up to 7-90:
  disconnect OXS harness connector 1
  touch wire to control unit (arrow) for approx. 20 seconds
     touch ground (-) if necessary, using jumper leads from VW 1594 adaptor kit




For vehicles built after 8-90:
    disconnect OXS (4 pin) harness connector and OXS heater 1, mounted on right
    engine mount
    touch violet wire from control unit (arrow) to ground for approx. 20 seconds using
    jumper leads from VW 1594 adaptor kit
If control current changes
    replace OXS sensor (G 39), see section 25-30
    read and then erase Fault memory, see Repair Group D2 for additional information
If control current does not change
    perform Electrical Test Step 13 in Repair Group D2 and/or replace control unit (J
    204)
    read and then erase Fault memory, see Repair Group D2 for additional information
For vehicles built after 10-90 starting with control unit:
49 States - 8A0 907 404
California - 893 907 404Q
  connect VAG 1551. Diagnostic Tester using VAG 1551/1 adaptor cable as follows
  connect VAG 1551/1 black connector to black diagnostic connector 1 in vehicle
      display must appear on tester
Note
If a display does not appear; do not connect white connector. There is a problem with the vehicle
power supply to the VAG 1551. Check using wiring diagram, repair or replace as necessary.
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Oxygen sensor and Oxygen sensor control, checking (Page 25-100-3)


After display "V.A.G SELF-DIAGNOSIS" appears
   connect white VAG 1551 connector to brown and/or white diagnostic connector 2 in
   vehicle
   start engine and let idle
   press 1 to enter "rapid data transfer"
   press 0 and 1 to select "engine electronics"
   press Q button to enter
   press      key
   press 0 and 8 buttons to select function "read measurement block"
   press Q button to enter input
      display will appear as shown

Read measurement block              HELP
Input display group number XX


  press 0 button twice to select "Display group 00"
     0 display will appear as shown

Read measurement block                   Q
Input display group number 00


  press Q button to enter input
     display will appear as shown

Read measurement block
1 2 3 4 5 6 7 8                 9   10


Continue with testing if the value displayed in channel 1 is less than 63 which corresponds to a
coolant temperature of at least 80 C (176 F)
  read OXS signal value in channel 6
      display must fluctuate
If YES
    press     button
    press 0 and 6 button to select function "end output"
    press Q button to enter input
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Oxygen sensor and Oxygen sensor control, checking (Page 25-100-4)




If display does NOT fluctuate
   disconnect OXS sensor (4-pin) and OXS heater harness connectors
       mounted on right engine mount (arrow)




   touch violet wire from control unit (arrow) to ground for approx. 20 seconds using jumper wires
from VW 1594 adaptor kit
      value displayed in channel 6 must increase
If YES
    replace OXS sensor (G 39), see section 25-30
    read and then erase Fault memory, see Repair Group D2
If display value does not increase
    perform Electrical Test Step 13 in Repair Group D2 and/or replace CIS-E Motronic
    control unit (J 204)
    read and then erase Fault memory, see Repair Group D2 for additional information
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  After start, warm-up and acceleration enrichment, checking (Page 25-110-1)


Note
Acceleration enrichment can also be checked using the VAG 1551 for vehicles built after 10-90
starting with control units:
49 states: 8A0 907 404
California: 893 907 404Q
Requirements
       engine coolant temperature 60 C (140 F) minimum
       no faults stored in Fault memory (all faults "repaired" and memory erased)
  switch OFF ignition
  switch Fluke 83 multimeter to mA range
  disconnect differential pressure regulator (N 71) harness connector




  connect test adaptor VAG 1315A/1 between differential pressure regulator and
  harness connector (arrows)
  connect multimeter to test adaptor VAG 1315A/1 using jumper leads from VW 1594
  adaptor kit
  switch ON ignition
     control current polarity (90-110 mA) must be positive (+); if not, swap test
     connections




For vehicles built up to 7-90:
  disconnect OXS sensor single pin harness connector (arrow)
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  After start, warm-up and acceleration enrichment, checking (Page 25-110-2)




For vehicles built after 8-90:
  disconnect 4-pin harness connector for Oxygen sensor probe and probe heater,
  mounted on right engine mount (arrow)
  disconnect coolant temperature sensor (G 62) connector




  set digital potentiometer VAG 1630 to 2500 Ohms and connect to disconnected
  harness connector using jumper leads from VW 1594 adaptor kit
  start engine and let idle
      control current must be 10 to 25 mA for approx. 6 to 9 seconds, then control current
      must again slowly drop back to 5 to 15 mA.
  fully (and quickly) open throttle and then close to provide a burst of fuel
       control current must rise briefly
    read and then erase Fault memory, see Repair Group D2.
If specified values are not obtained:
    perform Electrical Test A in Repair Group D2 and/or replace CIS-E Motronic control
    unit (J 204)
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Deceleration fuel shut-off, checking (Page 25-120-1)


Note
Deceleration fuel shut-off can also be checked using the VAG 1551 for vehicles built after 10-90
starting with control unit:
49 states: 8A0 907 404
California: 893 907 404Q
Requirements
       engine coolant temperature 60 C (140 F) minimum
       no faults stored in Fault memory (all faults "repaired" and memory erased)
  switch OFF ignition
  switch Fluke 83 multimeter to mA range
  disconnect differential pressure regulator (N 71) harness connector




  connect test adaptor VAG 1315A/1 between differential pressure regulator and
  harness connector (arrows)
  connect multimeter to test adaptor VAG 1315A/1 using jumper leads from VW 1594
  adaptor kit
  switch ON ignition
     control current polarity (90-110 mA) must be positive (+), if not; swap test
     connections
  start engine and increase engine speed in excess of 3000 RPM
  close throttle suddenly
      control current polarity must briefly become negative
    read and then erase Fault memory, see Repair Group D2
If control current does NOT become negative
    perform Electrical Test A in Repair Group D2 and/or replace CIS-E Motronic control
    unit (J 204)
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Acceleration enrichment and deceleration fuel shut-off, checking (Page 25-130-1)


For vehicles built after 10-90 starting with control unit:
49 states - 8A0 907 404
California - 893 907 404Q
Requirements
      engine cold
      A/C switched OFF
Vehicles with automatic transmission:
      selector lever in "P or N setting"




  connect VAG 1551 Diagnostic Tester using VAG 1551/1 adaptor cable as follows
  connect VAG 1551/1 black connector to black diagnostic connector 1 in vehicle
     display must appear on tester
Note
If no display appears; do not connect white connector. There is a problem with the vehicle power
supply to the VAG 1551. Check using wiring diagram, repair or replace as necessary.
After display "VAG SELF-DIAGNOSIS" appears
    connect white VAG 1551 connector-to brown and/or white diagnostic connector 2 in
    vehicle
    start engine and let idle
    operate VAG 1551 depending on display:
    press 1 button to enter "rapid data transfer"
  press 0 and 1 buttons to enter "engine electronics"
  press Q button to enter input
  press     button
  press 0 and 8 buttons to enter "read measurement block" function
  press Q button to enter input
     display will appear as shown

Read measurement block          HELP
Input display group number XX


  press 0 button twice to select display group 00
     display will appear as shown
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Acceleration enrichment and deceleration fuel shut-off, checking (Page 25-130-2)



Read measurement block                   Q
Input display group number 00


  press Q button to enter input
     display will show fields 1 through 10

Read measurement block
1 2 3 4 5 6 7 8                 9   10


Acceleration enrichment, checking
Perform this check only if channel 9 display value is greater than 96 which corresponds to a
coolant temperature below 60 C (140 F).
  observe display value in channel 9
  quickly open throttle to wide open position and then close again
      display value of 70 must appear briefly
The value displayed in channel 9 is the sum of the operating conditions present. This sum is a
result of adding together the various conditions present using the following assigned values:
Full throttle switch closed =                                    2
+ vehicles with manual or automatic
  transmission =                                                 4
+ acceleration enrichment activated =                           64

 = displayed value in channel 9                                 70

If value of 70 is not obtained
    perform idle and full throttle switch functional test, see section 25-210
Deceleration fuel shut-off, checking
Note
Perform this check only if channel display value in channel 1 is less than 95 which corresponds to
a coolant temperature of at least 60 C (140 F).
   observe display in channel 9
   raise engine speed in excess of 3000 RPM
   close throttle suddenly
       displayed value of 133 must appear briefly
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Acceleration enrichment and deceleration fuel shut-off, checking (Page 25-130-3)


The value displayed in channel 9 is the sum of the operating conditions present. This sum is a
result of adding together the various conditions present using the following assigned values:
Idle switch closed =                                         1
 + vehicles with manual or automatic
   transmission =                                            4
 + deceleration fuel shut-off activated =                  128
 = displayed value in channel 9                            133

    read additional values in channel 9 in Function "Measurement block, reading", see
    Repair Group D2 for additional information
If displayed value of 133 is obtained
    press     button
    press 0 and 6 buttons to enter function: "end output"
    press Q button to enter input.
If displayed value of 133 is not obtained
    perform idle and full throttle switch functional test, see section 25-210
    perform electrical testing, Repair Group D2 and if necessary replace CIS-E Motronic
    control unit (J 204)
    read and then erase Fault memory, see Repair Group D2 for additional information
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Speedometer speed signal, checking (Page 25-140-1)


For vehicles built after 10-90 starting with control unit:
49 states: 8A0 907 404
California: 893 907 404Q
Note
For vehicles built before 9-90, check the speedometer speed signal using Electrical Test step 22
in Repair Group D2.
For vehicles with manual transmission:
   place shift lever in neutral position
For vehicles with automatic transmission:
   place selector lever in "N" position
   raise left front wheel




    connect VAG 1551 Diagnostic Tester using VAG 1551/1 adaptor wire as follows:
    first connect black connector from VAG 1551/1 to black diagnostic connector 1
    after display "VAG SELF-DIAGNOSIS" appears, connect white connector from
    VAG 1551/1 to brown and/or white diagnostic connector 2
If display does not appear; do not connect white connector
    check voltage supply to VAG 1551 using wiring diagram

  switch ignition ON
  press 1 button to enter "rapid data transfer"
  press 0 and 1 for address word "engine electronics"
  press Q button to enter input
  press     button
  press 0 and 8 buttons to obtain "Read measurement block" function
  press Q button to enter input
     display will appear as shown

Read measurement block          HELP
Input display group number XX


  press 0 button twice to select display group 00
     display will appear as shown
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Speedometer speed signal, checking (Page 25-140-2)



Read measurement block                   Q
Input display group number 00


  press Q to enter input
     display shows channels 1 through 10

Read measurement block
1 2 3 4 5 6 7 8                 9   10


  observe speed signal value in channel 8
  manually rotate left front wheel
     value must fluctuate between 0 and 1 minimum
If specified value is obtained:
    press     button
    press 0 and 6 buttons to enter "end output" function
    press Q button to enter input
If specified values are not obtained:
    perform multifunction indicator troubleshooting, see Repair Group 91
    read and then erase Fault memory, see Repair Group D2
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Coolant temperature sensor, checking (Page 25-150-1)


The following procedure applies to vehicles built after 10-90 starting with control units:
49 states: 8A0 907 404
California: 893 907 404
For vehicles built before 9-90 check the speedometer signal by performing electrical test steps 8
and 23 in Repair Group D2
Requirements
      engine cold




    connect VAG 1551 Diagnostic Tester using VAG 1551/1 adaptor wire as follows:
    first connect black connector from VAG 1551/1 to black diagnostic connector 1
    after "VAG SELF-DIAGNOSIS" display appears, connect white connector from VAG
    1551/1 to brown and/or white diagnostic connector 2
If display does not appear; do not connect white connector
    check voltage supply to VAG 1551 using wiring diagram
    start engine and let idle
    press 1 button to enter "rapid data transfer"
    press 0 and 1 for address word "engine electronics"
    press Q button to enter input
    press      button
    press 0 and 8 buttons to obtain "Read measurement block" function
   press Q button to enter input
        display will appear as shown

Read measurement block          HELP
Input display group number XX


  press 0 button twice to select display group 00
      display will appear as shown

Read measurement block           Q
Input display group number 00


  press Q to enter input
     display shows channels 1 through 10
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Coolant temperature sensor, checking (Page 25-150-2)



Read measurement block
1 2 3 4 5 6 7 8           9   10


  observe value in channel 1
     value must drop uniformly and without interruption
If YES
    press     button
    press 0 and 6 buttons to enter 06 function "end output"
    press Q button to enter input
If channel 1 display does not drop uniformly (without interruption)
    replace coolant temperature sensor (G 62) and/or CIS-E Motronic control unit (J
    204)
    read and then erase Fault memory, see Repair Group D2.
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Cold start valve, checking (Page 25-160-1)


Function, checking
  perform output checks, see Repair group D2 for additional information
Spray pattern, injection time, and leakage, testing
  disconnect harness connector from ignition coil power output stage
  disconnect intake air boot from throttle body
CAUTION!
The sensor plate must not be raised during starting because catalytic converter damage
could result.
  disconnect coolant temperature sensor (G 62) harness connector




  preset VAG 1630 digital potentiometer to 15000 Ohms and connect to disconnected
  harness connector using jumper leads from VW 1594 adaptor kit




  remove cold start valve (N 17) and place in a measuring glass
WARNING!
Fire Hazard! Do not smoke or have anything in area that can ignite fuel.
   operate starter
      cold start valve must spray (pulse) for approx. 8 seconds in a uniform pattern
  dry off tip of cold start valve at nozzle
      within one minute; no drops may fall from the valve tip nor may any fuel dampness
      be present on tip surface
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Air flow sensor, checking and adjusting (Page 25-170-1)


WARNING!
Fire Hazard! Do not smoke or have anything in area that can ignite fuel.
Sensor plate lever and control plunger, checking
   pull injectors out of inserts and place in openings of VAG 1348/2B fuel analyzer
   operate either starter or remote control VAG 1348/3A for approx. 10 seconds
      to connect remote control, see section 25-190




  check quality of sensor plate lever movement by lifting sensor plate bolt using magnet
     sensor plate lever must exhibit same resistance over entire travel
  pull sensor plate upward with a quick movement using a magnet on the sensor plate bolt

      no change in lever resistance should be felt
If YES
    replace air flow sensor assembly
If sensor plate lever is difficult to move upward but moves downward easily
    replace fuel distributor
       control plunger is hanging up
Sensor plate rest position, checking




  upper edge of sensor plate must be dimension "a" below cone edge of venturi
     a= 1.9 + 1.1 mm
Sensor plate rest position, adjusting
  remove upper section of air filter housing and remove air filter element.
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Air flow sensor, checking and adjusting (Page 25-170-2)




  adjust rest position clearance (dimension "a") using adjustment nut (arrow)
     a=1.9 + 1.1 mm
CAUTION!
Do not bend leaf spring while performing adjustment.
Sensor plate free play, checking
Requirements
     sensor plate rest position OK
     CO adjustment OK, for checking see idle adjustment, section 25-210




Note
Free play is the clearance between the control plunger and sensor plate lever (right arrow),
measured on the side of the sensor plate closest to the fuel distributor (left arrow).
  operate starter or remote control VAG 1348/3A for approx. 10 seconds
      to connect remote control, see section 25-190
  lift sensor plate slightly until resistance is felt
        free play: 0.5 mm minimum
       3.0 mm maximum (up to edge of venturi)
If free play NOT OK
    adjust free play on fuel distributor via control plunger
Sensor plate free play, adjusting at fuel distributor
Requirement
     CO adjustment OK, for checking see idle adjustment, section 25-190
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Air flow sensor, checking and adjusting (Page 25-170-3)




   adjust sensor plate free play using wrench VW 674/2 on control plunger stop screw
      distance "a" = 0.6 mm between stop screw and collar of hex hut
      1/4 turn     = approx. 1.3 mm of play at sensor plate
      turning in = increases free play
      turning out = decreases free play
After free play adjustment is completed
   re-check free play adjustment, if necessary adjust CO content via control current
   adjustment, see idle adjustment, section 25-190
Sensor plate lever, basic adjustment
Note
The basic adjustment should only be performed if the fuel distributor or air flow sensor have been
replaced.




  measure distance between the air flow sensor housing opening (for the fuel
  distributor) and the sensor plate lever roller, if necessary adjust using CO adjusting
  screw
     must be 21.3    0.1 mm*
*After adjusting CO content to specifications (via control current), this dimension no longer
applies.
Control plunger, removing
  mark position of stop screw by scribing




    measure and record distance "a" between stop screw and hex nut collar
    remove stop screw using VW 674/2 wrench
Control plunger, installing
  wash control plunger with clean gasoline before installing
  inspect stop screw sealing ring for damage, replace if necessary
     install with smaller diameter 0 of sealing ring towards control plunger
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Air flow sensor, checking and adjusting (Page 25-170-4)




  insert stop screw using VW 674/2 wrench until previously recorded dimension "a" is
  obtained
  check sensor plate rest position and free play, adjust if necessary, see section 25-
  170
Note
Mechanically cleaning the control plunger is not permitted. If the piston shows heavy scoring
and/or does not move easily after washing with clean gasoline, the complete fuel distributor must
be replaced.
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Air flow sensor potentiometer, checking and adjusting (Page 25-180-1)


Note
The potentiometer is precisely adjusted at the factory; to prevent tampering and/or adjustments
the trim and mounting screws are then covered with sealing compound.
Requirements
       engine coolant temperature 60 C (140 F) minimum
       do not take measurements during periods when radiator cooling fan is running
Potentiometer, checking
  disconnect harness connector from air flow sensor potentiometer




  connect VAG 1501 test adaptor between potentiometer (G 19) and potentiometer
  harness connector (arrows)
  switch Fluke 83 multimeter to 20 Volt range
  connect multimeter to adaptor wires 1 and 3 of VAG 1501 test adaptor using jumper
  wires from VW 1594 adaptor kit
  switch ON ignition
     must be 4.35 to 5.35 Volts
  switch OFF ignition




  connect multimeter to adaptor wires 2 and 3 of VAG 1501 test adaptor
  start engine and let idle for 2 minutes minimum
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Air flow sensor potentiometer, checking and adjusting (Page 25-180-2)




  measure voltage and compare to chart
    U1=voltage measured between adaptor leads 1 and 3
    U2=voltage between adaptor leads 2 and 3
If U2 voltage falls below tolerance limit
   check intake system for air leaks
      between air flow sensor and cylinder head
      between possibly damaged connector pipe and intake air boot/throttle body
      at carbon canister solenoid valve
If a leak is detected and U2 voltage exceeds tolerance slightly
    carefully remove sealing compound covering potentiometer trim screw




  adjust U2 voltage using trim screw (arrow)
     try to obtain a nominal voltage within the shaded area of the chart
If an acceptable adjustment is not possible
    replace air flow sensor assembly
    cover trim screw with a dab of silicon adhesive sealing compound
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Fuel pressure, checking (Page 25-190-1)


WARNING!
Fire Hazard! Do not smoke or have anything in area that can ignite fuel.
Requirements
     fuse No. 18 OK
     fuel pumps OK, checking - Repair Group 20
     whenever a fuel line is disconnected always replace the sealing rings
VAG 1318 pressure tester, connecting




  connect VAG 1318 pressure tester to measuring point 1 of fuel distributor using
  adaptor VAG 1318/4
  disconnect fuel line 2 from cold start valve (N 17) and connect to VAG 1318
  pressure tester
     shut-off valve on pressure tester:
     Position A - open
     Position B - closed
     Remote control VAG 1348/3A, connecting




  remove fuel pump relay (J 17) from fuse/relay panel, location 12
  attach VAG 1348/3-2 adaptor wire connector to terminal 4 of fuel pump relay socket
  in location 12
  connect alligator clip for remote control VAG 1348/3A to battery positive (+)
System pressure, checking
    open VAG 1318 shut-off valve (position A) and operate remote control VAG
    1348/3A
       system pressure must be 6.1 to 6.6 bar
If system pressure is not obtained or is too low
    replace fuel pressure regulator
If system pressure too high
    disconnect fuel return line from fuel pressure regulator and provide container to
    catch overflow
    repeat test
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Fuel pressure, checking (Page 25-190-2)


If system pressure OK
    check return line for proper flow, repair or replace as necessary
If system pressure too high
    replace fuel pressure regulator
Differential pressure, checking
    close VAG 1318 shut-off valve (position B)
    disconnect harness connector from differential pressure regulator (N 73)
    operate remote control VAG 1348/3A
       differential pressure must be 0.3 to 0.5 bar below system pressure
If differential pressure NOT OK
    disconnect thin line from fuel pressure regulator and hold in measuring container
    cover or plug open connection on fuel pressure regulator
    operate remote control VAG 1348/3A for 1 minute and measure accumulation
       must be 130 to 150 cc's
If NO
    replace pressure regulator
    reconnect thin line on fuel pressure regulator
If differential pressure OK
    switch Fluke 83 multimeter to 2 Amp range
    disconnect harness connector from differential pressure regulator




    connect test adaptor VAG 1315A/1 between harness connector and differential
    pressure regulator
    connect multimeter to test adaptor VAG 1315A/1 using adaptor leads from VW 1594
    adaptor kit
    switch ON ignition
       control current must be 90 to 110 mA
    operate remote control VAG 1348/3A
       differential pressure must be 1.3 to 1.6 bar below system pressure
If differential pressure NOT OK
    replace differential pressure regulator
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Fuel pressure, checking (Page 25-190-3)


If differential pressure and control current not OK
    perform Electrical Test A in Repair Group D2, and/or replace CIS-E Motronic control
    unit (J 204)
Residual pressure, checking
Note
This check is required only if there are hot start problems.
    operate remote control VAG 1348/3A for approx. 5 seconds
    observe pressure drop on VAG 1318 gauge
       after 10 minutes, there must be a minimum pressure of 3.3 bar
       after 20 minutes, there must be a minimum pressure of 3.2 bar
If the pressure drop exceeds these specifications
    check fuel pump check valve, see Repair Group 20
    check sensor plate free play and adjust if necessary, see section 25-170
    check fuel distributor sealing rings, replace if necessary
If these checks are OK
    replace fuel pressure regulator
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Injection quantity comparative measurement (Page 25-200-1)


WARNING!
Fire Hazard! Do not smoke or have anything in area that can ignite fuel.
Requirement
     fuse 18 OK
Remote control VAG 1348/3A, connecting




  remove fuel pump relay (J 17) from fuse/relay panel, location 12
  attach VAG 1348/3-2 adaptor wire connector to terminal 4 of fuel pump relay socket
  in location 12
  connect alligator clip for remote control VAG 1348/3A to battery positive (+)
  carefully pull fuel injectors out of their inserts and place complete set into openings
  of VAG 1348/2B fuel analyzer
      ensure that fuel lines are routed smoothly and without kinks




  turn and lift adjusting screw 1, slide 2 and knurled nut 4 of sensor plate positioning
  tool VAG 1348/1A to upper position
  place tool centrally on edge of air flow sensor with point 3 of tool facing fuel
  distributor
  hold air flow sensor plate in rest position by hand
  push slide 2 in to stop
  turn adjusting screw 1 in until magnetic tip contacts sensor plate mounting bolt

  operate remote control and turn adjusting screw 1 out far enough so that start of
  spray becomes visible at one of the injectors
  switch off remote control and empty analyzer
     fuel injectors remain inserted in analyzer
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Injection quantity comparative measurement (Page 25-200-2)


Idle position, fuel injection quantity measuring




  pull slide 2 of VAG 1348/1A to first stop (idle simulation)
  observe spray pattern of injectors during following step
     spray pattern must be the same for all injectors
     if spray pattern for one injector is different; lift sensor plate up once briefly and
     repeat test
  operate remote control until 20 ml fuel accumulates in one of the tubes
  compare fuel quantities of injectors with each other while holding analyzer level
     maximum permissible deviation between all injectors: 2.0 ml

If fuel quantity between highest and lowest reading differs more than 2.0 ml
    interchange those two injectors and repeat test
If difference in quantity changes between the interchanged injectors
    replace those injectors
If injection quantity remains the same after interchanging injectors
    check if fuel line is pinched or if fuel distributor is defective, repair or replace as
    necessary
Full throttle position, fuel injection quantity measurement
  empty VAG 1348/2 fuel analyzer
      fuel injectors remain inserted in analyzer




  pull slide 2 of VAG 1348/1A to second stop (full throttle simulation)
  observe spray pattern of injectors during following step
  spray pattern must be the same for all injectors
  if spray pattern for one injector is different; lift sensor plate up once briefly and
  repeat test
operate remote control until 8.0 ml fuel is obtained in one of the tubes
compare fuel quantities of injectors with each other while holding analyzer level
  maximum permissible deviation between all injectors: 8.0 ml
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Injection quantity comparative measurement (Page 25-200-3)


If fuel quantity between highest and lowest reading differs more than 8.0 ml
    interchange those two injectors and repeat test
If difference in quantity changes between the interchanged injectors
    replace those injectors
If injection quantity remains the same after interchanging injectors
    check if fuel line is pinched or if fuel distributor is defective, repair or replace as
    necessary
Leak checking
  place air flow sensor plate at rest position
  operate remote control for approx. 2 minutes
     fuel injectors must not drip
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Idle and full throttle switches, checking and adjusting (Page 25-210-1)


For vehicles with separate idle and full throttle switches.
For vehicles built after 10-90 starting with control units:
49 states: 8A0 907 404
California: 893 907 404Q
The function of the idle and full throttle switches can also be checked using the VAG 1551
Diagnostic Tester, see functional check later in this section.
  disconnect harness connector from idle/full throttle switch connector




  connect VAG 1501 test adaptor to idle/full throttle switch connector
    wiring harness connector remains open
Idle switch (F 60), checking and adjusting
   switch Fluke 83 multimeter to resistance range




  connect multimeter to adaptor leads 1 and 2 using jumpers from VW 1594 adaptor
  kit
      must be 0 Ohms
  open throttle slightly
      idle switch must switch OFF and resistance must increase to infinite Ohms
  close throttle slowly and while doing so check switching point of idle switch using
  feeler gauge
      throttle body free play: between operating lever and throttle lever
      throttle body without free play: between throttle lever and idle stop (limiter screw)
      switch point "a" must occur between 0.15 mm and 0.5 mm as measured between
      throttle valve lever and stop screw
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Idle and full throttle switches, checking and adjusting (Page 25-210-2)


  adjust switch point "a" if necessary, by loosening and moving idle switch (F 60) until
  specification is obtained
  re-tighten idle switch mounting screws and re-check
Note
To ensure proper switching of idle switch, check operating levers for freedom of movement.
Full throttle switch (F 81), checking and adjusting
  connect multimeter between adaptor test leads 2 and 3 using jumpers from VW
  1594 adaptor kit
      must be infinite Ohms
  open throttle completely
      idle switch must switch on and resistance decrease to 0 Ohms




  mount 3084 protractor on throttle body shaft (2nd stage) and fasten using magnetic
  adapter 3084/1
Note
If throttle shaft (2nd stage) is attached with a mounting nut place the protractor without the 3084/1
magnetic adapter on the throttle shaft and if necessary remove the mounting nut.
    open throttle fully by hand




  close throttle by approx. 30 then push slowly back in direction of full throttle stop
  (arrow), while doing so check switching point (0 Ohms) of full throttle switch 2
     switch point 10 2 before full throttle stop
  adjust switch point if necessary by moving full throttle switch 2 as necessary, then
  re-check
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Idle and full throttle switches, checking and adjusting (Page 25-210-3)


The following procedures are for vehicles with idle switch, full throttle switch and throttle
potentiometer contained in one assembly located below the throttle body.
Idle and full throttle switches, checking and adjusting
For vehicles built after 10-90 starting with control unit:
49 states: 8A0 907 404
California: 893 907 404Q
The idle and full throttle switches can also be checked using the VAG 1551 Diagnostic Tester,
see functional check later in this section.
      if the potentiometer is replaced in a vehicle with an automatic transmission, the
      automatic transmission control unit must "learn" the voltage value of the new
      potentiometer by returning the system to its basic setting, see Repair Group D2 for
      additional information.
Idle and full throttle switches, checking




  connect VAG 1501 test adaptor to idle/full throttle switch connector (white)
      harness connector remains disconnected
  switch Fluke 83 multimeter to resistance range
  connect multimeter to adaptor leads 1 and 2 using jumpers from VW 1594 adaptor
  kit
      must be 0 Ohms
  open throttle slightly
  idle switch must switch OFF and resistance increase to infinite Ohms




slowly close throttle while checking switch point (0 Ohms) of idle switch with feeler
gauge between throttle lever and idle stop (limiter screw)
   switch point "a" = 0.15 mm to 0.5 mm before idle stop
measure resistance between adaptor leads 2 and 3
   must be infinite Ohms
open throttle completely
   full throttle switch must switch on and resistance decrease to 0 Ohms
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Idle and full throttle switches, checking and adjusting (Page 25-210-4)


Idle and full throttle switches, adjusting
Note
The switching point of the idle switch is the only adjustment possible. The full throttle switch and
potentiometer become adjusted as a result of adjusting the idle switch and are not adjusted
separately.
   remove throttle body
   remove heat shield




  loosen potentiometer 1 (arrows)
  rotate and hold potentiometer first clockwise and then fully counterclockwise
  (carefully) up to stop
CAUTION!
Turn potentiometer using very light force otherwise the throttle will open.
  tighten potentiometer in this position and check switching point as described in
  section 25-180
Idle and full throttle switches, functional testing
For vehicles built after 10-90 starting with control unit:
49 states: 8A0 907 404
California: 893 907 404Q
Requirements
      A/C switched OFF
      selector lever in "P or N setting" (vehicles with automatic transmission)
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Idle and full throttle switches, checking and adjusting (Page 25-210-5)




    connect VAG 1551 Diagnostic connector using VAG 1551/1 adaptor cable as
    follows
    first connect black VAG 1551/1 connector to black diagnostic connector 1
    after "V.A.G SELF-DIAGNOSIS" display appears; connect white VAG 1551/1
    connector to brown and/or white diagnostic connector 2
If display does not appear; do not connect white connector
    check voltage supply to VAG 1551 using wiring diagram
    switch ignition ON
    press 1 button to enter "rapid data transfer" mode
    press 0 and 1 buttons to enter "engine electronics"
    press Q button to enter input
    press      button
    press 0 and 8 buttons to enter function "read measurement block"
    press Q button to enter input
        display will appear as shown

Read measurement block          HELP
Input display group number XX


  press 0 button twice to select "Display group number 00"
     display will appear as shown

Read measurement block            Q
Input display group number 00


  press Q button to enter input
     display shows channels 1 through 10
Read measurement block
1 2 3 4 5 6 7 8               9   10


  observe display value in channel 9
  displayed value must be 5
Note
The value displayed in channel 9 is the sum of the operating conditions present. This-sum is a
result of adding together the various conditions present using the following assigned values:
Idle switch closed =                                         1
 + vehicles with manual or automatic
   transmission =                                            4
 = displayed value in channel 9                              5
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Idle and full throttle switches, checking and adjusting (Page 25-210-6)


  open throttle slightly
    idle switch must switch on and display in channel 9 must change to 4
Idle and full throttle switches open =                      0
 + vehicles with manual or automatic
   transmission =                                           4
 = displayed value in channel 9                             4

  open throttle completely
    full throttle switch must switch and display value in channel must change to 6
Full throttle switch closed =                               2
+ vehicles with manual or automatic
  transmission =                                            4

 = displayed value in channel 9                             6

Note
Read additional values in channel 9 in Function "Measurement block, reading", see Repair Group
D2 for additional information.
If the required display values are obtained
    press     button
    press 0 and 6 buttons to enter "end output" function
    press Q button to enter input
If required display values are not obtained
    perform electrical testing, Repair Group D2 and if necessary replace CIS-E Motronic
    control unit (J 204)
    read and then erase Fault memory, see Repair Group D2 for additional information
  Volkswagen B3 Passat
  Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
  Intake air preheating, checking (Page 25-220-1)


Control flap, checking
Requirement
     no leaks in control flap vacuum unit
  loosen air filter housing upper section and remove air filter element




  position air filter housing upper section such that the control flap in the lower section
  housing can be seen
  disconnect vacuum unit hose from temperature controller on intake air boot
  connect vacuum unit hose to US 8026 hand vacuum pump

  operate vacuum pump to check control flap freedom of movement and vacuum unit
  function
     control flap must close OFF cold air pipe 1
Temperature regulator, checking
  connect vacuum unit hose to temperature controller connector nipple on intake air
  boot




  start engine and let idle
     position of control flap after 20 seconds (maximum), depending on temperature
     controller temperature:
     below approx. 20 C (68 F) = cold air pipe 1 closed
     above 30 C (86 F) = warm air pipe 2 closed
     between 20 C and 30 C (68 to 86 F) = control flap between cold and warm air
     pipes (both pipes open)
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
Vacuum connections (Page 25-230-1)




 1 - from carbon canister
     carbon canister system repairing see Repair Group 20
 2 - Carbon canister solenoid valve I (N 80)
     gray
 3 - Carbon canister solenoid valve II (N 115)
     black
 4 - Intake air boot
 5 - Temperature controller
     note installed position
 6 - Throttle body
 7 - Intake manifold
 8 - Check valve
        for vehicles without ABS only
        note installed position: arrow on valve points toward intake manifold
 9 - from brake booster
     for vehicles without ABS only
10 - from multifunction indicator - A/C
        for vehicles without ABS only
        vehicles without multifunction indicator - AC: plug off connection on check valve (item
        8)
11 - from multifunction indicator
        for vehicles with ABS
        for vehicles without multifunction indicator: plug off connection on tee
Volkswagen B3 Passat
Fuel Supply-Fuel Injection-Exhaust-Ignition 4 CYL.
Vacuum connections (Page 25-230-2)


12 - from A/C
        for vehicles with ABS
        for vehicles without A/C, plug off connection on tee
13 - from temperature regulator
        Item 5
        for vehicles with ABS
14 - from idle stabilizer valve (N 71)
     see section 25-50. Item 19
15 - Vacuum unit
     for intake air preheating control flap
16 - Air filter housing

				
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