Contents: Assembly location diagram ⬇ Assembly diagram of a fuel…⬇ Air filter assembly diagram ⬇ Throttle valve control mechanism…⬇
Assembly location diagram
The parts marked with letters A and B are not shown in the figure.
- A - Accelerator pedal position sensor "G79" and accelerator pedal position sensor 2 "G185", in the footwell on the accelerator pedal (both sensors are located in the same housing)
- B - Lambda probe behind the G130 exhaust gas catalytic converter, behind the main exhaust gas catalytic converter
1 - vacuum regulating valve (PCV valve), on the timing gear cover; 2 - Valve injectors: valve injector of the 1st cylinder "N30", valve injector of the 2nd cylinder "N31", valve injector of the 3rd cylinder "N32", valve injector of the 4th cylinder "N33", on the fuel distributor; 3 - Intake air pressure sensor "G71" and intake air temperature sensor "G42", on the intake manifold; 4 - Knock sensor 1 "G61", on the rear of the cylinder block; 5 - Solenoid valve 1 for the N80 activated carbon tank, on the gas inlet line; 6 - throttle valve control mechanism "J338", with throttle actuator "G186", throttle position sensor "G187" and throttle position sensor 2 "G188", on the intake manifold; 7 - Engine speed sensor "G28", on the rear sealing gasket of the crankshaft flange, on the intake side; 8 - Hall sensor "G40", on the camshaft housing; 9 - Coolant temperature sensor "G62", in the coolant temperature regulator housing; 10 - Control unit "Motronic" "J623" with an atmospheric pressure sensor; 11 - Thermal switch for additional cooling fan "F18", to the left at the lower neck of the radiator; 12 - Four-pin plug connector for the G39 lambda probe and lambda probe heating before the exhaust catalytic converter, in the plug connector holder near the starter; 13 - Lambda probe "G39", before the exhaust gas catalytic converter; 14 - Ignition coils with final power stage: ignition coil 1 with final power stage "N70", ignition coil 2 with final power stage "N127", ignition coil 3 with final power stage "N291", ignition coil 4 with final power stage "N292"; 15 - Valve 1 for rearranging the camshaft "N205" assembly diagram of the intake manifold
1 - Intake gas pipeline; 2 - O-ring, replace; 3 - 7 Nm; 4 - Throttle control mechanism "J338", in case of replacement, adapt the engine control unit to the throttle control mechanism; 5 - Air bleed hose from the activated carbon tank; 6 - Electromagnetic valve 1 for the N80 activated carbon tank, secured with a holder on the intake gas line, the valve is activated by clock pulses from the engine control unit; 7 - Air bleed hose; 8 - 20 Nm; 9 - Intake hose to the brake booster; 10 - O-ring seal, replace if damaged; 11 - Coolant hose to the crankcase ventilation system heater; 12 - Spring clamp; 13 - Crankcase ventilation system heater (engine crankcase), for removal and installation, the gas inlet pipe must be removed; 14 - 3 Nm; 15 - Hose to the vacuum control valve of the engine crankcase ventilation system (to the oil separator); 16 - O-ring seal, replace; 17 - Intake air pressure sensor "G71" with intake air temperature sensor "G42"
Assembly diagram of a fuel distributor with valve injectors
1 - Secure the fuel supply hose from the fuel filter with spring clamps, making sure it is securely installed; 2 - 7 Nm; 3 - Retaining clamp, ensure correct installation; 4 - Cable duct (Guide piece), pressed in by clamps on the fuel distributor; 5 - Fuel distributor; 6 - Air valve, fuel device; 7 - Protective cap, air valve; 8 - Bracket, ensure correct installation on the valve injector; 9 - O-ring, replace before installing, lubricate lightly with clean engine oil; 10 - Valve injectors "N30", "N33", resistance: 12.0-17.0 Ohm (at room temperature)
Air filter assembly diagram
1 - 3 Nm. The upper and lower parts of the air filter are connected using self-tapping screws. Loosening or tightening these screws with a machine impact wrench may damage the parts being connected. Therefore, it is permitted to use a machine impact wrench only if the following conditions are met: the rotation speed of the impact wrench is max. 200 rpm, tightening torque max. 3 Nm.; 2 - Upper air filter element; 3 - Sealing ring; 4 - One-way valve; 5 - Hose to the camshaft housing; 6 - Inlet hose; 7 - Spring clamp, use spring clamp pliers to remove and install; 8 - Sealing ring; 9 - Rubber bushing; 10 - Lower air filter element; 11 - Filter element
Throttle valve control mechanism cleaning "J338"
Important: If a new J623 engine control unit is installed, it must be adapted to the J338 throttle control mechanism. This adaptation can only be performed with a new or cleaned J338 throttle control mechanism, as carbon deposits in the areas where the closed throttle valve contacts the fitting can cause erroneous adaptation values. The throttle body fitting must not be scratched during cleaning.
Remove the air filter housing. Remove the throttle control mechanism. Open the throttle valve with your hand and lock it in the open position with a suitable object (eg with a plastic or wooden wedge) "arrow".
Caution: Do not use compressed air to clean the throttle valve.
Clean the throttle valve fitting thoroughly with standard acetone according to DIN 53247 and a brush, especially in the areas where the closed throttle valve "arrow" meets.
Wipe the throttle body with a non-shedding cloth. Allow the acetone to dry completely and reinstall the cleaned throttle control mechanism. Adapt the engine control unit "J623" to the throttle control mechanism "J338".
