Ignition system components, removing and installing

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2002 Volkswagen Jetta, 2002 Volkswagen GTI, 2001 Volkswagen Jetta, 2001 Volkswagen GTI, and 2000 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Exploded View Of Ignition System Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - O-ring

Always replace

2 - Camshaft Position (CMP) sensor G40

Checking → Camshaft Position (CMP) sensor G40 , checking
Installation location → Component locations, overview , engine compartment overview
Sensor and harness connector contacts are gold-plated

3 - 10 Nm

4 - Harness connector

Black, 3-pin
Camshaft Position (CMP) sensor G40
Sensor and harness connector contacts are gold-plated

5 - Cable guide

6 - Harness connector

5-pin
For Ignition coil N152

7 - Ignition coil N152

With ignition cable identification; do not interchange
Checking → Ignition coils with power output stage, checking
Installation location → Component locations, overview , engine compartment overview

8 - Cover

Removing and installing: → 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK

9 - Harness connector

Brown, 3-pin
For Knock Sensor 2 G66
Sensor and connector contacts are gold-plated

10 - 20 Nm

Tightening torque influences function of knock sensor

11 - Knock Sensor (KS) 2 G66

Sensor and connector contacts are gold-plated
Located on intake side of cylinder block
Checking → Knock sensors, checking

12 - Sender wheel

For Camshaft Position (CMP) sensor G40
Contact surface of timing chain and sensor wheel must be dry when installing
If sensor wheel has been removed, after installing check timing: → 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK

13 - Camshaft chain sprocket

14 - Camshaft roller chain

15 - Knock Sensor (KS) 1 G61

Sensor and harness connector contacts are gold-plated
Located on exhaust side of cylinder block
Checking → Knock sensors, checking

16 - Harness connector

White, 3-pin
For Knock Sensor (KS) 1 G61
Sensor and harness connector contacts are gold-plated

17 - 100 Nm

Oil bolt head contact surface when installing
To remove and install, counter-hold using 24 mm spanner on camshaft

18 - Spark plug

25 Nm
Remove and install using 3122B spark plug spanner
Type and electrode gap → Technical data, spark plugs , test data, spark plugs

19 - Spark plug connector with ignition cable and suppressor

4-6 kΩ
Only remove and install spark plug connector using tool T10029