Work Procedure
1990-92 (49-States) GLI 16V/GTI 16V and Standard Transmission Passat VehiclesA. Check/Replace Engine ECM
- Connect VAG 1551 tester and check vehicle's engine ECM part number.
- If part number reads 8A0 907 404CC, ECM unit is correct.
- If reading shows any other part number, remove ECM and install replacement ECM, part number 8A0 907 404CC.
Important:
Attach the tester print-out to the repair order hard copy for future reference.
B. Install Throttle Linkage Clip
- Check throtle body linkage for previously installed clip.
- It present, proceed to "Check Idle Switch Operation".
- If clip is not present, continue as follows:
^ Check throttle body linkage for gap between idle switch actuation arm and throttle arm. See Illustration I.
If linkage has no gap, proceed to "Check Idle Switch Operation".
If a gap is visible, install linkage clip, part number 051 133 806A follows:
^ slide clip into gap as shown in illustration II.
^ ensure that tabs on clip are past idle switch actuation arm.
^ use needle nose pliers to bend tabs to retain clip.
C. Check Idle Switch Operation
- Disconnect throttle switch connector.
- Connect VAG 1501 test harness.
- Use VW 1594/2 and Ohm meter with 1501 test harness.
D. Replace Air Suction Pipe (GLI 16V/GTI 16V Models Only)
- Remove air suction pipe and replace with new pipe, part number 027 133 373P.
- Reuse clamps.
E. Secure Fuel Lines
- Check injector fuel lines for proper seating in clips. If not inserted into clips, check shape of fuel lines and reshape as necessary.
- Insert reshaped fuel lines into clips and ensure proper retention.
F. Trim A/C Line Foam Tube
- On vehicles with air conditioning, the A/C line protective foam tubing needs to be trimmed slightly (see arrow in Illustration III) to gain additional clearance between tubing and air flow meter potentiometer connector.
- Use razor blade or similar for trimming.
G. Check Basic Engine Adjustment
- Use VAG 1551 tester and check basic engine adjustments; refer to Workshop Manual, Group 25.