Safety Precautions

The increased demands on the ignition systems of modern engines and the desire for maintenance free operation have lead to the introduction of electronic ignition systems. As a rule, the sparking power of an electronic system is higher than a conventional system; additional increases in performance are characteristic of this type of system.

When working on the electronic ignition system (DI), the following safety precautions must be observed:

• Before performing work that requires cranking the engine (e.g. compression test) turn OFF ignition and disconnect connector 2 on the DI control module (N1/3) or connect safety plug, part number 102 589 02 21 00, to diagnostic socket.
• Perform installation work on the ignition system or ignition wires only when the engine/ignition is turned off (as well as connecting/disconnecting sensors only with the ignition switched off).
• No exposed metal connectors or sending units may be installed in the ignition wires (e.g. ignition wire, cylinder 1).
• To avoid damage to the DI control module (N1/3), connect/disconnect the control module connectors only when the ignition is turned OFF.
• Do not connect a test lamp to circuit 1 of the ignition coil.
• Circuit 1 of the ignition coil may not be shorted to ground, e.g. theft deterrence.
• To avoid reversing polarity, the threads on the ignition coil have different diameters (M5 and M6).
• Only original equipment components should be installed in the ignition system.
• Do not operate the ignition system at cranking speed unless the ignition harness is completely connected.
• To avoid damage to the DI control module (N1/3), the high output side of the ignition system must carry at least 2Kohm of load (distributor rotor 1000 ohm, each connection on the distributor cap 1000 ohm). Do not install a 5000 ohm distributor rotor for noise suppression.
• Do not perform any tests (grounding ignition cable 4, disconnecting a spark plug connector or pulling cable 4 out of the ignition coil) at cranking or idle speed.
• To better dissipate heat, the DI control module (N1/3) is installed with thermal paste on the wheel well. When exchanging the control module, do not remove the foil shield, it does not influence heat dissipation.
• If the circuit breaker is activated (power balance test), and the engine stalls, then the test procedure with this tester cannot be performed.
• When testing the ignition coil separately, do not load the coil with more than 28 kV in order to avoid damage to the coil.
• If assisting a disabled vehicle and is becomes necessary to perform an ignition spark test, perform this test only on one ignition cable/spark plug. Ensure good ground connection to the spark plug.