Section A
Section A - 2.8 Liter Engine in Jetta and GTIIMPORTANT:
- If the vehicle has a MIL light on, the diagnostic trouble codes (DTCs) must be checked
- Only cylinder misfire DTCs related to ignition coil malfunction are covered by this service action. Any other checking, diagnosis or repairs are not part of or covered under this service action
- If applicable, connect VAS5051 and check DTCs
- Open hood and remove engine cover
- Disconnect connector from all ignition coils -1-
- Using Puller T10095, remove ignition coils
CAUTION: USE OF TOOL T10095 IS REQUIRED TO AVOID DAMAGING THESE SENSITIVE COMPONENTS
NOTE: Only ignition coils that are not one of the production levels shown on Page 2 "Parts Information" must be replaced
- Install new ignition coils (022 905 100D/G/K) by pressing into cylinder head by hand only
IMPORTANT:
- Do not use any object to tap ignition coil into position
- Do not twist ignition coil when installing
- Reconnect connectors to ignition coils
- Reinstall engine cover
- If vehicle is a 2002 model year Jetta with automatic transmission go to Section A1
- If vehicle is a 2003 model year Jetta with automatic transmission go to Section A2
- If vehicle is a Jetta or GTI with manual transmission go to Section A3
Section A1 - Wiring Harness Modification on 2002 Model Year Jetta Vehicles having a 2.8 Liter Engine with an Automatic Transmission
- Disconnect battery ground (GND) cable
- Remove relay cover -arrow- for relay panel (located next to brake booster) in engine compartment
- Remove fuse (S51) -white arrow- for vacuum pump from fuse holder
- Remove relay #428 for the main power supply to the engine control module (ECM) -black arrow-
- Lift out relay panel from the lower housing
- Turn relay panel over to access wiring to fuse and relay
- Remove large wire from cavity #1 for fuse (S51) -arrow-
- Illustration to the right shows large wire -arrow- removed from cavity #1
- Remove red connector block (for relay #428) -arrow- from the relay housing
- Locate large wire -3- from cavity 2 of the red connector for relay #428 and cut wire approximately 30 mm from terminal
NOTE: Cavity numbers are located on the connector at the terminal insertion points
- Strip insulation from wire ends using VAS 1978/3 wire strippers from the VAS 1978 repair kit
NOTE: The illustrations show the large wire installed in the relay connector housing. It may be easier to remove this terminal from the relay connector housing for the following modification
- Using new repair wire (000 979 227), cut wire approximately 100 mm from the terminal and strip the insulation from the wire (other end of the repair wire is not needed)
- Insert the new 100 mm long repair wire -1- along with the end (30 mm length) of the previously cut wire -3- (from connector block cavity 2) into one end of a butt connector -4- (111 971 938 A)
- Crimp the butt connector using the VAS 1978/2 crimper from the VAS 1978 repair kit
- Insert remaining end of previously cut wire -3- into the other end of the butt connector -4- and crimp using the wire crimper
- Seal the butt connector using the electric hot air blower
- If the large wire was removed from the relay connector housing cavity #2 to do this modification, reinstall wire at this time
- Install the wire previously removed from the fuse holder (for fuse S51) cavity #1 into an unused cavity of the fuse holder (this wire is no longer used)
NOTE: In this illustration, cavity #4 was used -white arrow- however, your vehicle may be different
- Install terminal from the 100 mm repair wire into the cavity #1 -black arrow- of the fuse holder
- Reinstall red connector block for relay into relay panel
- Reinstall relay panel into lower housing
- Reinstall relay #428 and fuse (S51) into relay panel
- Reinstall relay cover
- Reconnect battery ground (GND) cable and tighten nut to 6 Nm (53 in. lbs.)
- Proceed to Section A3
Section A2 - Wiring Harness Modification on 2003 Model Year Jetta Vehicles Having a 2.8 Liter Engine with an Automatic Transmission
NOTE:
- Use harness kit (1J0 971 658N). If not obtainable, the harness can be assembled
- Some parts are in the VAS 1978 wiring harness repair kit; other parts need to be ordered (Reference "Parts Information" on Page 2)
- Instructions for harness assembly are in Section A4
IMPORTANT: The terminal ends on the wire harness from the kit or from the assembled harness are shown to correspond to the terminal connection numbers on the relay connector
- Open driver's door, remove instrument panel side cover -1-
- Remove 2 screws -2- unclip trim panel -3- and remove
- Remove 2 screws -2a- unclip trim panel -4- and remove
- Remove (6) screws -arrows- and remove reinforcement -5-
- Unclip and remove lower cover -6- by sliding rearward out of clips
- Using a volt meter, check the terminal contacts of the 15 amp fuse in position B -arrow- for 12 volts or B+ power) and make note of terminal position in fuse housing
- Under hood, remove battery cover and disconnect battery ground (GND) cable
- Remove fuse/relay holders -A- and -C- (arrows) at the bottom of the lower relay panel
- Remove fuse holder -B- from the bottom of lower relay panel -arrow- and remove fuse from holder
- Remove (2) nuts -A- and pull lower relay carrier rearward and down to remove
- Remove the B+ terminal (as previously found) from fuse holder B -arrow-
NOTE: The illustration shows the wire removed from position #2, however, your vehicle could be different
- Insert the B+ terminal (removed from fuse holder) into terminal housing -11- (191 972 751 or 1J0 972 751)
NOTE: The terminal housing 1J0 972 751 comes with the wiring harness assembly
IMPORTANT: To insert the B+ terminal into the 1J0 972 751 housing, the side clip needs to be opened
NOTE: This terminal housing -11- will be connected to a terminal housing -2- on the new wiring harness later in the procedure
- From the rear of the upper half of the relay panel, insert the new relay connector block on the new harness assembly into position #9 -arrow-
NOTE: The new relay must be removed from the relay connector on the new harness assembly before installing
- Route wires 2, 6 and 8 on the new harness assembly behind the fuse/relay panels
- Locate terminal -8- (arrow) on the new wiring harness assembly
- Insert terminal 8 on the new wire harness into the empty (B+) location in the 15 amp fuse holder -arrow-
- Remove (red) connector block -arrow- (for relay position 3) on reverse side of lower relay carrier
- Remove terminal from position number 3 -arrow- of red connector block
- Insert this terminal -3- into connector housing -11A- (191 972 751 or 1J0 972 751)
NOTE: The terminal housing 1J0 972 751 comes with the wiring harness assembly
IMPORTANT: To insert terminal -3- into the 1J0 972 751 housing, the side clip needs to be opened
- Connect the housing -11A- to the connector housing -4- on the new harness assembly
- Locate terminal -3A- (arrow) [short wire from connector housing -4-] on new harness assembly
- Insert terminal -3A- into the empty position number 3 -arrow- of red connector
- Reinstall red connector block to reverse side of relay panel (behind relay position 3)
- Reinstall relay carriers, secure with (2) nuts -A- and tighten to 2 Nm (18 in. lbs.)
- Insert the connector -11- (contains terminal removed from B+ fuse connector at the start of this procedure) to connector -2- (arrow) on the new wire harness assembly
- Reinstall fuse holder to location -B- on the lower relay block
- Reinstall 15 amp fuse
- Reinstall fuse/relay holders -A- & -C- into proper location on lower relay block
- Locate ground (GND) wire -6- (eyelet terminal on the new wiring harness assembly)
- Remove cap nut at ground point -arrow- near steering column, install ground wire eyelet -6- from new harness assembly, secure with cap nut and tighten to 6 Nm (53 in. lbs.)
- Install new (141 951 253 B) relay into upper relay block position 9 -arrow-
- Reinstall instrument panel lower cover
- Reinstall reinforcement and secure with (6) screws
- Reinstall lower trim panels
- Reinstall instrument panel side cover
- Reconnect battery ground (GND) cable and tighten to 6 Nm (53 in. lbs)
- Reinstall battery cover
- Proceed to Section A3
Section A3 - Repair verification and readiness code setting
- If a wiring harness was modified, turn ignition switch "ON" and "OFF" before first starting engine, then:
- Start vehicle and verify correct operation
- Remove key and wait up to 30 seconds to ensure that the vacuum pump does not run
- Set engine readiness code and power restoration procedure
- If a wiring harness was not modified and the MIL light was on with cylinder misfire DTCs present, printed and erased, use VAS5051 and set engine readiness code
- Attach a copy of print out for diagnostic log (showing cylinder misfire DTCs) and readiness code "Test Complete" to repair order
NOTE: Readiness code setting is not related to this action when other components related to the MIL light are diagnosed and repaired
- Destroy and properly dispose of removed ignition coils
Section A4 - Wiring Harness Assembly
NOTE: This section is needed only if the wiring harness assembly 1J0 971 658 N is not obtainable
- Using a repair wire -2- (000 979 227), cut wire approx. 100 mm from terminal, insert wire in butt connector -A- (111 971 939 B) and crimp butt connector with the VAS 1978/2 crimper
- Using a repair wire -1- (000 979 220), cut wire approx. 100 mm from terminal, insert wire in butt connector -A- and crimp butt connector
- Seal the butt connector using the electric hot air blower from the VAS 1978 repair kit
- Insert terminal end of wire -2- into position 2 -arrow- of relay connector -12- and wire end -1- into a terminal housing -10- (191 972 761)
- Using a repair wire -4- (000 979 114), cut wire approx. 150 mm from terminal
- Using a repair wire -5- (000 979 135), cut wire approx. 80 mm from terminal
- Insert ends of wire -4- and -5- into butt connector -A- and crimp connector
- Using a repair wire -3- (000 979 130), cut wire approx. 70 mm from terminal, insert wire in butt connector -A- and crimp butt connector
- Seal the butt connector using the electric hot air blower
- Insert terminal end of wire -4- into position 4 -arrow- of relay connector -12- and terminal end of wire -5- into terminal housing -10- (191 972 761)
- Using repair wire -6- (000 979 114), cut wire approx. 30 mm from terminal, insert into butt connector -A- and crimp connector
- Using repair wire -7- (000 979 137), cut wire approx. 330 mm from eyelet, insert into butt connector -A- and crimp connector
- Seal the butt connector using the electric hot air blower
- Insert terminal end of wire -6- into position 6 of relay connector -12-
- Using repair wire -8- (000 979 227), cut wire approx. 110 mm from eyelet, insert into butt connector -A- and crimp connector
- Using repair wire -9- (000 979 227), cut wire approx. 110 mm from eyelet, insert into butt connector -A- and crimp connector
- Seal both ends of the butt connector using the electric hot air blower
- Insert terminal end of wire -8- into position 8 of relay connector -12-
- Go to Section A2 for harness installation