CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...

4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

28 – Ignition system
1 Repairing ignition system
General notes on ignition system ⇒ page 552 .
Safety precautions ⇒ page 552 .
Assembly overview - ignition system ⇒ page 553 .
Removing and installing ignition coils with output stages
⇒ page 553 .
Spark plug test data ⇒ page 556 .

1.1 General notes on ignition system

♦ The battery must be disconnected only with ignition switched
off. If a coded radio is installed, ascertain code before discon‐
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♦ For trouble-free operation of electrical components, a voltage

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of at least 11.5 V is necessary.

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♦ After completing work, read event memory of engine control

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unit. Clear all events that may have been recorded while
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checks and repairs were carried out. If the event memory was
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cleared, the readiness code must be generated ⇒ Vehicle di‐

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♦ If, after fault finding, repairs or component tests, the engine

starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
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In this case, the control unit must be adapted ⇒ Vehicle diag‐

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1.2 Safety precautions

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To prevent injuries to persons and/or damage to the injection and

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ignition system, the following must be observed:

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♦ Do not touch or pull off ignition coils with output stage when
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♦ Switch off ignition before connecting or disconnecting injection

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memory after completion of work.
♦ Always switch off ignition before cleaning engine.
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, otherwise the engine control unit
could be damaged.
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test instruments and measuring equipment must always be
secured to the rear seat and operated by a second person from
this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a

552 Rep. gr.28 - Ignition system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.

1.3 Assembly overview - ignition system

1 - Knock sensor 1 - G61-

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❑ Removing and installing
⇒ page 553

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4 - Spark plug, 25 Nm
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❑ Type and electrode gap

⇒ page 556 .
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❑ Remove and install with

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spark plug socket and

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⇒ page 456
❑ Removing and installing
⇒ page 555
7 - 10 Nm
8 - Hall sender - G40-
❑ In cylinder head cover at front.
❑ Gold-plated contacts

1.4 Removing and installing ignition coils

with output stage
Special tools and workshop equipment required

1. Repairing ignition system 553

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Puller - T40039-

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♦ Observe all relevant safety precautions ⇒ page 552 .

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♦ Assembly overview - ignition system ⇒ page 553 .

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♦ To pull off spark plugs, fit puller - T40039- on top, thick rib
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♦ If the lower ribs are used, they could be damaged.
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– Pull all ignition coils about 30 mm out of spark plug recess
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using puller - T40039- .

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– Release connectors and pull all connectors off ignition coils

-arrows- at the same time.
Installing ignition coils with output stages
– Fit all ignition coils loosely into spark plug holes.

554 Rep. gr.28 - Ignition system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Align the ignition coils with the connectors -arrows- and attach
all connectors onto ignition coils simultaneously.
– Press ignition coils onto spark plugs by hand with uniform
pressure.

1.5 Removing and installing knock sensor 1

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– Remove coolant
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The knock sensor I - G61- is located under the intake manifold

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– Remove bolts of knock sensor I - G61- and remove it.
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– Install in reverse order of removal.

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• Torque setting ⇒ page 553 .

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1.6 Removing and installing engine speed

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sender - G28-
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– Remove engine cover.

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– Open hose clip -2- of air pipe.

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– Disconnect electrical connector -arrow-. t. C rig
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– Remove noise insulation ⇒ General body repairs, exterior;
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– Undo and remove bolts -1 and 4- and pull air hose downwards
off throttle valve module - J338- .

1. Repairing ignition system 555

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Pull air hose -1- off charge air cooler and take air pipe out
downwards.

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– Detach electrical connector -1- from engine speed
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– Undo and remove bolt securing engine
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Install in reverse order of removal, observing the following.
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• Torque setting ⇒ Item 6 (page 553) .

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1.7 Test data, spark plugs

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Engine code BZB, CAWA, CAWB, CBFA, CCTA,
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CCTB, CGYA, CCZA, CCZB, CCZC,

CCZD, CDAA, CDAB

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Firing order 1-3-4-2

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Spark plugs
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VW/Audi For part numbers, see ⇒ Electronic

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parts catalogue (ETKA)

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Electrode gap 0.8 mm

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Torque setting Cop
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556 Rep. gr.28 - Ignition system