Parts of ignition (vehicles with engine codes BDF and BJS), removing and installing

WARNING: This page does not describe the selected car, but rather 14 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen R32, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, and 2003 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Overview Of Ignition Components (Vehicles With Engine Code BDF And BJS)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: Motronic Engine Control Module (ECM) -J220- with harness connectors. Refer to Parts of fuel injection (vehicles with engine codes BDF and BJS), removing and installing , item 8

1 - Connector

Black, 4-pin
before disconnecting, mark allocation of connector to component

2 - Ignition Coil 1 with Power Output Stage -N70-*, Ignition Coil 2 with Power Output Stage -N127-*, Ignition Coil 3 with Power Output Stage -N291-*, Ignition Coil 4 with Power Output Stage -N292-*, Ignition Coil 5 with Power Output Stage -N323-* and Ignition Coil 6 with Power Output Stage -N324-*

Component location. Refer to Overview of Component Locations (vehicles with engine codes BDF and BJS) , component locations overview
Removing and installing. Refer to Ignition coils with power output stages (vehicles with engine codes BDF and BJS), removing and installing
checking. Refer to Ignition coils with power output stages (vehicles with engine code BDF and BJS), checking

3 - Control housing

For camshaft adjustment
Removing and installing:

Refer to 15 - ENGINE - CYLINDER HEAD, VALVETRAIN for 2.8 LITER VR6 2V ENGINE MECHANICAL, ENGINE CODE (S): AFP, 15 - ENGINE - CYLINDER HEAD, VALVETRAIN for 2.8 LITER VR6 4V ENGINE MECHANICAL, ENGINE CODE(S): BDF or 15 - ENGINE - CYLINDER HEAD, VALVETRAIN for 3.2 LITER VR6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BJS

4 - Bracket

For harness connector of Knock Sensor (KS) 1 -G61-

5 - 10 Nm

6 - 3-pin harness connector

black
Terminals are gold-plated

7 - Knock Sensor (KS) 1 -G61-*

Component location: between cyl. 1 and cyl. 3
contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease
checking. Refer to Knock sensors, checking

8 - 20 Nm

Tightening torque affects function of Knock Sensor (KS)

9 - Exhaust camshaft adjuster

Identification: 32A
Only rotate engine with camshaft adjuster installed
with sensor wheel for Camshaft Position (CMP) Sensor 2 -G163-
If camshaft adjuster has been removed, check timing after installation:

10 - 60 Nm + 1/4 additional turn (90 °)

replace
Contact surface of sensor wheel at bolt head must be dry when installing
To remove and install, counter-hold at camshaft using an open-end wrench (32 mm)

11 - Cover piece

12 - Seal

replace

13 - Camshaft Position (CMP) Sensor 2 -G163-*

Component location. Refer to Overview of Component Locations (vehicles with engine codes BDF and BJS) , component locations overview
For exhaust camshaft
Terminals of sensor and connector are gold-plated
checking. Refer to Camshaft Position (CMP) sensor, checking

14 - 10 Nm

15 - Connector

black, 3-pin
Terminals of sensor and connector are gold-plated
before disconnecting, mark allocation of connector to component

16 - Camshaft Position (CMP) Sensor -G40-*

Component location. Refer to Overview of Component Locations (vehicles with engine codes BDF and BJS) , component locations overview
for intake camshaft
Terminals of sensor and connector are gold-plated
checking. Refer to Camshaft Position (CMP) sensor, checking

17 - Knock Sensor (KS) 2 -G66-*

Component location: between cyl. 4 and cyl. 6
contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease
Terminals of sensor and connector are gold-plated
checking. Refer to Knock sensors, checking

18 - Connector

black, 2-pin
Terminals of sensor and connector are gold-plated

19 - Camshaft roller chain

Mark direction of travel (installation position) before removing

20 - Intake-camshaft adjuster

Identification: 24E
Only rotate engine with camshaft adjuster installed
With sensor wheel for Camshaft Position (CMP) Sensor -G40-
If camshaft adjuster has been removed, check timing after installation:

21 - Camshaft Adjustment Valve 1 (exhaust) -N318-*

For exhaust camshaft
before disconnecting, mark allocation of connector to component
Check valves for camshaft adjustment. Refer to Valves for camshaft adjustment (vehicles with engine codes BDF and BJS), checking

22 - Valve 1 for camshaft adjustment -N205-*

for intake camshaft
before disconnecting, mark allocation of connector to component
Check valves for camshaft adjustment. Refer to Valves for camshaft adjustment (vehicles with engine codes BDF and BJS), checking

23 - Spark plug

Type and spark plug gap. Refer to Test data, spark plugs , test data, spark plugs

Vehicles with engine code BDF:

25 Nm

Vehicles with engine code BJS:

20 Nm