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VW AIR-COOLED TECH FAQ's or Frequently Asked Questions
WATER-COOLED TECH FAQ's or Frequently Asked Questions

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  Tech Data
Wiring Terminal Identification by Number 
Next time you pull a relay or a switch and look at the numbers and wonder what they mean you will wish you had this list. I only wish I had had it 20 years ago.
OXSensors diagnosis

Recalls(free work) History of the Beetle
 
Type I VIN and Engine Numbers 
 
Type II VIN and Engine NumbersI
 
Type III VIN and Engine Numbers
 
Changes in the Type I over the years
 
Changes in the Type II over the years
 
Changes in the Type III over the years
 
Changes in the Type IV over the years
 
Specs for the Type I

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OXYGEN SENSORS* - TESTING and MAINTENANCE
*General info that would apply to all cars, not just VW

The Oxygen sensor or sensors are installed downstream in the exhaust system and generate a small voltage signal (usually less than 1 volt) that increases when the air/fuel mixture goes rich and decreases when the air/fuel mixture goes lean. This "voltage message" is then sent to the Engines computer so that the computer can fine tune the mixture adjustment by regulating fuel quantity, ignition advance etc.

                              Knowing what's bad
Typically, a bad O2 sensor will read low voltage (lean), which causes the engine to run too rich. A low reading can be caused by several things:
1) Old age
2) Contamination

      A) engines burn oil
      B) an internal coolant leak
3) A bad wiring connection
4) An ignition or compression problem in the engine
5) Also an O2 sensor ages. It can be sluggish and not react as fast as it once did so it doesn't need to fail completely to be bad.

                              Heater
1) Sensor needs to operates at 617 to 662
degree minimum to produce voltage
2) If heater fails sensor will still operate but computer will not go into closed loop mode until it gets to operating temp

                              Common Diagnosis
Response and and voltage output can be monitored with:
1) A scan tool
2) A voltmeter
3) Digital oscilloscope
4) Replacement is necessary, cleaning is useless

                                 Testing
1) Disconnect OXSensor lead and connect voltmeter
2) Enrich mixture with propane in the intake until engine speed drops
to 200 rpm or by disconnecting vacuum line to fuel pressure regulator and plug vacuum line
3) Voltmeter should rapidly read .9 volts
4) Test lean response by opening a small vacuum leak
5) Voltmeter should rapidly read .2 volts or below
6) To check the sensors dynamic performance reconnect the sensor lead and run the engine at 1500 rpm
7) Sensor output should fluctuate around .5 volts
8) Monitor sensor signal with a scope at 2500 rpm
10) The signal should fluctuate approximately .2 to .8 volts in less than 300 milliseconds

                     Replacement Recommendations

1) Unheated 1 or 2 wire sensoors (76 to early 90s) 30,000 to 50,000 miles
2) Heated 3 and 4 wire sensors (mid 80s to thru mid 90s) 60,000 miles
3) 96 and newer OBD II vehicles 100,000 miles recommended
       A) 96 and newer sensor mounted behind cat to monitor the efficiency of the converter.

VW Tech Support
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