Campaign - Replace Ignition Coil Cable: Overview
NOTQ
DATE
July 1997
Subject:
1993-95 Model Golf/Jetta and
1995 Cabrio Vehicles with 2.0L
Engine Replace Ignition Coil Cable
Dear Volkswagen Dealer:
This is to inform you of a service action campaign involving 1993-95 model Volkswagen 2.0L Golf/Jetta vehicles and 1995 model 2.0L Cabrio vehicles. The repair pertains to the replacement of the ignition coil cable.
Problem Description
It is possible that the ignition coil cable presently installed in affected vehicles could under certain climate conditions misfire (spark jumping).
Vehicle Identification Number Range
The vehicles affected are within the following vehicle identification number ranges:
Please note that the VINs represent the lowest and highest serial numbers of affected vehicles. Use of the V-Crest campaign inquiry system will allow you to determine whether or not a particular vehicle, within the above VIN range, requires the corrective work.
NOTE: Volkswagen will not reimburse under this service action any duplicate repair work or a repair outside the VIN range.
Model Numbers
Remedial Action
Replace ignition coil cable and check proper routing of spark plug cables and brake booster vacuum hose.
Important: Please inform and/or provide a Copy to All Personnel With Recall-Related Responsibilities!
Owner Notification Mailing
Volkswagen will mail first class notification letters to all known owners of affected vehicles on or about July 9, 1997. A copy of the owner letter is enclosed in this circular.
Vehicle Allocation
By separate mail and prior to owner notification, we will furnish you a computer list containing information for vehicles and owners located within your area of responsibility.
IMPORTANT NOTE: This listing includes owner names and addresses obtained from California motor vehicle registrations. Under the law set forth by the California Department of Motor Vehicles, vehicle registration information may only be used for recall purposes. Use for any other reason may constitute a violation of state law.
Work Procedure
IGNITION CABLE REPLACEMENT
^ Open hood
^ Locate, remove and discard the ignition coil cable and coil cable bracket (if present) close to ignition coil
^ Replace with a new cable -A- from a kit, part number 037 998 031
^ Connect the angled end of the new ignition coil cable to the coil
^ Route the ignition coil cable under the accelerator cable -D- and between spark plug cables for cylinders # 1 and # 3 at the distributor
^ Connect the straight end of the ignition coil cable to the distributor cap
^ Install ignition coil cable holding clip from the kit to the radiator overflow hose -B-
- The clip location must be a minimum of 80 mm (3.12 in.) from cylinder head
- Secure the ignition coil cable to the clip
^ If present, remove and discard the spark plug cable separator located above the distributor cap Route the cylinder # 4 spark plug cable at the distributor cap between the spark plug cable of cylinders # 1 and # 3
CAUTION: SPARK PLUG CABLES MUST NOT TOUCH TOGETHER. ENSURE SUFFICIENT DISTANCE BETWEEN SPARK PLUG CABLES.
^ After ignition coil cable installation, adjust the holding clip so the ignition coil cable does not come in contact with any components
^ The vacuum hose that is routed behind the ignition coil must be rerouted to the front of the ignition coil as follows:
- Disconnect the vacuum hose from the brake booster vacuum line, route the hose in front of the coil and in such a way that the hose does not touch any engine components
- Reconnect the vacuum hose to the brake booster vacuum line
- Remove the present brake booster vacuum hose securing clip close to the brake booster and discard
- Install new clip from the kit on the brake booster vacuum line and secure the other vacuum line in the clip according to -C- in the illustration (accelerator cable is no longer guided by a holding clip)
Discard all removed parts.
Parts Information
We will automatically ship to you an initial supply of the following parts, according to your vehicle allocation:
Description Part Number Application
Ignition Coil Cable Kit 037 998 031 1993-95 Golf/Jetta and 1995 Cabrio
Additional required parts must be ordered by you from your respective parts depot. Please refrain from over-ordering any of these parts; you may be required to return excess inventory.
Replacement Time/Reimbursement
To ensure proper payment, be sure to enter the reimbursement data only for VINs showing the TQ code in the V-Crest system.
TQ Data Entry Procedure
! IMPROTANT: Enter $7.00 in Sublet Labor field for vehicle Wash/Vacuum.
For vehicles which, according to your information are unreachable, please enter into the system one of the codes indicated, as applicable:
California Requirements
California Dealers / Owners Only
The California Air Resources Board and the Department of Motor Vehicles (DMV) require that this action be completed prior to the vehicle registration renewal. It is, therefore, imperative that upon completion of this repair you provide the owner with a signed "Proof of Correction" certificate. This certificate (Order # W42 002 3050) will accompany the owner notification letter.
Important Note: Please emphasize to owners the importance of retaining this certificate for their records and advise them NOT to mail it to the DMV unless requested.
Additional Campaigns
Some of the affected vehicles may also be involved in additional corrective actions. Please always check your V-Crest system so that any additional work can be completed simultaneously.
Dealer Obligation
To ensure customer satisfaction, as well as minimize inconvenience, dealers are urged to service each vehicle at the scheduled service appointment time and make sure that each vehicle is returned to the customer washed and cleaned inside. Do not let customers wait longer than necessary during service of the vehicle. Every effort should be made to reduce inconvenience to customers.
Dealers are to service each vehicle subject to this service action regardless of mileage, age of vehicle, or selling dealer, from this time forward.
Service Help
If you have any questions regarding this action or any other service action, please contact me at (248) 340-4850 or
Jerry Lasky (248) 340-4734
John von Hollen (248) 340-4858
Sheila Gailliard(248) 340-4855
Dealer Personnel Information
PLEASE INFORM AND/OR PROVIDE A COPY OF THIS COMMUNICATION TO EVERY PERSON IN YOUR DEALERSHIP WHO HAS CAMPAIGN-RELATED RESPONSIBILITIES1 INCLUDING ACCOUNTING PERSONNEL.
Thank you for your cooperation