2.0l 4-cyl 4v Turbo Generic Scan Tool - Motronic Fuel Injection System, Ignition System, Engine Code: Bpg Audi A4 B7

Fuel Supply System

For all Fuel Supply system component locations. Refer to --> 20 - FUEL SUPPLY SYSTEM

For all Fuel supply system removal/installation procedures and torque specifications. Refer to --> 20 - FUEL SUPPLY SYSTEM

Check the Technical Bulletins for information that may supersede any information included in this article.

Safety precautions

Perform the following steps before beginning work on the fuel supply system

1. Disconnect the battery Ground (GND) cable with the ignition switched off --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(ref-278931-S05223151852008020700000) for ELECTRICAL EQUIPMENT, CABRIOLET .
2. Open the fuel filler flap briefly and then close again.

When removing and installing components from full or partially full fuel tanks, observe the following

1. The fuel tank must only be partially full. How much fuel can remain in the fuel tank may be read in the respective work description. Empty the fuel tank if necessary.
2. Before starting work, switch on the exhaust extraction system and place an extraction hose close to the installation opening of the fuel tank to extract escaping fuel fumes. If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m 3 /h can be used.
3. Prevent fuel from contacting the skin! Wear fuel-resistant gloves!

Observe the following when removing and installing the fuel tank

1. Empty the fuel tank for weight reasons.

Rules for cleanliness

When working on the fuel supply/injection system, pay careful attention to the following rules of cleanliness

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place parts that have been removed on a clean surface and cover them. Do not use fluffy cloths!
3. Carefully cover over opened components or seal, if repairs are not performed immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpacked (e.g. in tool boxes etc.).

1. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.

Fuel pump delivery quantity, checking

Special tools, testers and auxiliary items required

1. Pressure gauge V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/12
4. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3

1. Fuel-resistant measuring container

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuel filter OK
3. Fuse on fuse panel S228 (position 28) OK.

Scheme 954

1. Fuel Pump (FP) Control Module J538 OK.
2. Fuel tank at least 1 / 4 filled.
3. Ignition switched off.

Scheme 955

Test sequence

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Unbolt cover for left locking flange - arrows -.

Scheme 956

1. Disconnect electrical harness connector - arrow - at right locking flange.

Scheme 957

1. Connect remote control V.A.G 1348/3 A with connection V.A.G 1348/3-3 to contact - 1 - using an adapter cable from connector test set V.A.G 1594 C.
2. Using insulating tape, tape over the second contact of connection V.A.G 1348/3-3 to prevent a short circuit - arrow -.
3. Connect contact - 4 - to vehicle Ground (GND) using a jumper cable from connector test set V.A.G 1594 C.
4. Connect alligator clip to vehicle battery (+).

Scheme 958

1. Remove fuel filler cap from fuel filler tube.
2. Remove engine cover - arrows -.

Scheme 959

1. Disconnect fuel line - arrow - from line connection on engine.

Scheme 960

1. Connect pressure gauge V.A.G 1318 to fuel supply line using adapters V.A.G 1318/11 and V.A.G 1318/12.
2. Connect extension hose - arrow - to pressure gauge and hold it in a measuring container.
3. Open shut-off valve of pressure gauge. The lever points in direction of flow.
4. Generate pressure in fuel system by pressing switch of remote control and slowly closing shut-off valve of pressure gauge.

1. Specification: 4 bar positive pressure.

1. From this point on do not move position of shut-off valve.
2. Empty measuring container.
3. Press switch on remote control for 15 seconds.

Scheme 961

1. Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approx. 2 volts less than battery voltage.

Installation is in reverse order of removal. Note the following

1. Install the fuel line.

Torque specifications

Fuel pump electrical, checking

Special tools, testers and auxiliary items required

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3.
2. Multimeter V.A.G 1526 B or equivalent.
3. Connector test set V.A.G 1594 C.

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuse S228 OK.
3. The Fuel Pump (FP) Control Module J538 OK .
4. The fuel filter OK

1. The ignition switched off.

Test sequence

1. Remove the rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Remove the right locking flange cover and bolts - arrows -.

1. Disconnect the electrical harness connector - arrow - at the right locking flange.
2. Connect remote control V.A.G 1348/3 A with connection V.A.G 1348/3-3 to contact - 1 - using an adapter cable from the connector test set V.A.G 1594 C.
3. Using insulating tape, tape over the second contact of connection V.A.G 1348/3-3 to prevent a short circuit - arrow -.
4. Connect contact - 4 - to vehicle Ground (GND) using a jumper cable from the connector test set V.A.G 1594 C.

1. Connect the alligator clip to the vehicle battery (+).
2. Press the switch on the remote control.

Note. The Fuel Pump (FP) runs quietly. Avoid surrounding noises while testing the fuel pump.

The fuel pump must run and an audible noise of the fuel pump running should be heard.

If no operating noise can be heard

1. Remove the fuel delivery unit. --> «20 - FUEL SUPPLY SYSTEM»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Scheme 962

1. Using multimeter V.A.G 1526 B or equivalent, check the electrical connections between the flange and the fuel pump.

Specified value: Wire resistance max 0 ohms.

If the specification is not obtained

1. Check the wiring for an open circuit.
2. If necessary, repair the wiring connection.

If no malfunction is detected in the wiring, replace the fuel pump. --> 20 - FUEL SUPPLY SYSTEM .

1. Install the fuel delivery unit --> «20 - FUEL SUPPLY SYSTEM»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Final procedures

After the repair work, the following work steps must be performed in the following sequence

1. Check the DTC memory.
2. If necessary, erase the DTC memory.
3. If the DTC memory was erased, generate readiness code.

1. End diagnosis and switch the ignition off.

EVAP system, leak detection

Function

The leak detection system recognizes leaks in the complete fuel system, including the fuel tank, EVAP canister and the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.

On the mechanical side, the leak detection system consists mainly of a vacuum-driven diaphragm pump equipped with a reed contact on the actuation rod of the pump diaphragm. The pump is supplied with vacuum via the engine intake stroke.

1. When leak detection is activated, the diaphragm pump pumps the fuel system up to 20 30 mbar. The pump diaphragm is then moved out so that the reed contact at the operating rod remains in the "open" position.
2. During the leak diagnosis, the reed contact is monitored to check if it remains open within 10 seconds. This indicates the system is sealed.
3. If the pressure falls (indicating a leak), the diaphragm moves back and the reed contact closes.
4. If the reed contact closes within 10 seconds of leak detection time, a further test is performed: In this case the diaphragm pump pumps four times again. The Engine Control Module (ECM) J623 measures the time for each of the four pumps until the reed contact is closed again. From that, the control module can recognize a "small leak" (greater than 1 mm in diameter) or a "large leak".

Leak diagnosis is activated automatically shortly following every engine start. If a malfunction is determined, an entry is made to the Diagnostic Trouble Code (DTC) memory. The Malfunction Indicator Lamp (MIL) K83 in the instrument cluster lights up if the malfunction is recognized for two subsequent starts.

Evaporative Emission (EVAP) canister system, checking for proper seal

Note. Secure all hose connections using hose clamps appropriate for the model type . Replace seals and gaskets when performing repair work.

Test sequence

1. Connect the diagnostic tester.
2. Start the engine and let run at idle for at least 15 minutes.
3. Select "Diagnostic mode 8: Tank leak test".
4. Select the "Test-ID 01: Tank leak test" and check the specified value at idle.

Specified value: test OK

Note. If the accelerator pedal is depressed during the test, the test will be aborted. To repeat the tank leak-tightness test, switch the ignition off, start the engine again, and let it run at idle.

If the specified value is obtained

1. End diagnosis and switch the ignition off.

If the specified value is not obtained

Checking fuel supply and tank ventilation systems for leaks

1. Check whether the fuel filler cap of the fuel tank was completely sealed for test.
2. Check whether the seal of the fuel filler cap was damaged or crimped. Replace if necessary.
3. Remove the rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

Scheme 963

1. Release the retaining tabs - arrows -.
2. Fold the retaining tabs open - 1 - and - 3 - toward the rear.

Scheme 964

1. Fold the cover - 2 - toward the front - arrow -.

Scheme 965

1. Unbolt the cover - arrows -.

1. Remove the bolts - arrows - and remove the cover for the locking flange, left and right.
2. Check whether the seals under the locking flanges are OK and the union nuts are properly tightened on the fuel tank. Also check the fuel line connections.
3. Visually check all hose connections of the fuel supply system and replace any leaking lines, e.g

1. Line from the EVAP canister to the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.
2. Lines from the EVAP canister to the Leak Detection Pump (LDP) V144.
3. Line from the fuel tank to the EVAP canister (below cover for EVAP canister).
4. Lines for the tank ventilation (beneath right rear wheel housing liner).

1. Fuel lines to the engine.

Note. Leaks at the lines and components of the fuel tank ventilation system can sometimes be located using a non-flammable, environmentally compliant leak detection spray. Initiate the leak diagnosis several times in sequence to build up pressure in the system. At leaking areas, bubbles will form.

1. Repeat the function test.

If a malfunction persists

1. Perform a visual inspection on the fuel system components and tank ventilation system.

1. Fuel tank
2. EVAP canister
3. Leak Detection Pump (LDP) V144
4. Evaporative Emission (EVAP) Canister Purge Regulator Valve N80

Note. Due to the form or function of the components, leaking areas may not always be localized by spraying on the leak detection spray. It may be necessary to clamp off the relevant component using Hose Clamps Up To 25mm Dia. 3094 and initiate the tank leak detection diagnostic. If the leak is no longer indicated, the component that was clamped off is faulty. If clamped off directly at the leak detection pump and a leak is still indicated, the leak detection pump itself is leaking.

Final procedures

After the repair work, the following work steps must be performed in the following sequence

1. Check the DTC memory.
2. If necessary, erase the DTC memory.
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Test requirements

1. The fuse for the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 OK.
2. The ignition switched off.

Note. Voltage for the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 is supplied via the Engine Component Power Supply Relay J757.

Procedure

1. Disconnect the electrical harness connector - 3 - from the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.

Checking internal resistance

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the resistance between the terminals of the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.

Specified value: 22,0 to 30,0 ohms.

If the specified value is not obtained

1. Replace the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.

Checking voltage supply

If the specification is obtained

Scheme 966

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the electrical harness connector terminal 1 to 2 for voltage.
2. Operate the starter briefly.

Specified value: aprox. battery voltage

If there is no voltage

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the electrical harness connector terminal for voltage.

1. Operate the starter briefly.

Specified value: aprox. battery voltage

If there is no voltage again

1. Check the wiring connection from the electrical harness connector terminal 1 to the Leak Detection Pump (LDP) -V144- terminal 3 for an open circuit according to wiring diagram.

Specified value: Wire resistance max 1.5 ohms.

1. If necessary, repair the wiring connection.

If the voltage supply is OK

Check Ground (GND) activation

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the electrical harness connector for voltage.

1. Operate the starter briefly.

Specified value: aprox. battery voltage.

1. Switch the ignition off.

If the specified value is not obtained

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Multimeter V.A.G. 1526 A or equivalent, the following wire connection for open circuit.

Specified value: Wire resistance max 1.5 ohms.

Specification: 0 ohms.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If the specification is obtained

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory.
2. If necessary, erase the DTC memory.
3. If the DTC memory was erased, generate readiness code.

1. End diagnosis and switch the ignition off.

Leak Detection Pump (LDP) V144 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Test requirements

1. The Leak Detection Pump (LDP) V144 fuse OK.
2. The ignition switched off.

Procedure

1. Remove the left rear wheel housing liner. --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

Scheme 967

1. Disconnect the electrical harness connector - 3 -.

Checking internal resistance

Scheme 968

1. Using the Multimeter V.A.G. 1526 A or equivalent, check them Leak Detection Pump (LDP) V144 for resistance as follows

If the specifications are not obtained

1. Replace the Leak Detection Pump (LDP) -V144-. --> «20 - FUEL SUPPLY SYSTEM»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

If the specified values are obtained

1. Check the voltage supply of the Leak Detection Pump (LDP) -V144-.

Checking voltage supply

Note. The voltage for the Leak Detection Pump (LDP) -V144- is supplied via the Engine Control Module (ECM) J623.

Scheme 969

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the electrical harness connector for voltage.

1. Operate the starter briefly.

Specified value: aprox. battery voltage.

1. Switch the ignition off.

If the specified value was not obtained

1. Using the Multimeter V.A.G. 1526 A or equivalent, check electrical harness connector terminal - 3 - via Fuel Metering Valve N290 to Engine Control Module (ECM) J623 for open circuit.

Specified value: Wire resistance max 1.5 ohms.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring and if the voltage supply was OK

Checking output wiring

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) The ECM is not connected.

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the following wire connections for an open circuit.

Specified value: Wire resistance max 1.5 ohms.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunction is found in wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Assembly is performed in the reverse order of the removal, note the following

1. Install the left rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory.
2. If necessary, erase the DTC memory.
3. If the DTC memory was erased, generate readiness code.

1. End diagnosis and switch ignition off.

Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. The Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185 is located in the accelerator pedal module and communicate the drivers intensions to the SIMOS Control Module J361 completely independently of each other. Both sensors are located in the accelerator pedal module and replaced as an entire assembly.

Test requirements

1. The fuses for the engine electronics OK.
2. The battery voltage must be at least 12.5 Volts.
3. All the electrical consumers such as, for example, lights and rear window defroster must be switched off.
4. The parking brake must be applied, otherwise the daytime running lights are switched on.

1. On vehicles with an automatic transmission, the selector lever must be in position "P" or "N".
2. If the vehicle is equipped with an A/C system, it must be switched off.
3. The ground (GND) connections between the engine and body must be OK.

Procedure

1. Remove the left knee bolster --> «68 - INTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «68 - INTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

Scheme 970

1. Disconnect the electrical harness connector - 2 -.

Checking voltage supply

1. Switch the ignition on.

Scheme 971

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the following wiring connections for voltage.

1. Switch the ignition off.

If the specified values are not obtained

Checking wiring connections

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the following wiring connections for open circuit.

Specified value: Wire resistance max 1.5 ohms.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring and if the voltage supply was OK

1. Replace the Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185. --> «20 - FUEL SUPPLY SYSTEM»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

If no malfunction is detected in the wiring and if the voltage supply was not OK

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Assembly is performed in the reverse order of removal, noting the following

1. Install the left knee bolster --> «68 - INTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «68 - INTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory.
2. If necessary, erase the DTC memory.
3. If the DTC memory was erased, generate readiness code.

1. End diagnosis and switch the ignition off.

Turbocharger

For all Turbocharger, G-Charger component locations. Refer to --> 21 - TURBOCHARGER, G-CHARGER

For all Turbocharger, G-Charger removal/installation procedures and torque specifications. Refer to --> 21 - TURBOCHARGER, G-CHARGER

Check the Technical Bulletins for information that may supersede any information included in this article.

General notes

1. Charge air system must be properly sealed. --> «21 - TURBOCHARGER, G-CHARGER»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
2. Always replace self-locking nuts.
3. Charge air hoses and pipes as well as their connections must be free of oil and grease before re-installing.
4. Do not assemble charge air hoses and lines with lubricants containing oils, only coat with water (without additives) if necessary.

1. Note installation marks on hoses and components.
2. All hose connections for charge air system are secured by spring-type clamps or by connector couplings.
3. Install only approved clamps for securing hose connections .
4. Pliers for spring clamps VAS 5024 A or Hose clamp pliers V.A.G 1921 are recommended for installing spring clamps.

1. For connector couplings, always note the following points

Scheme 972

1. Disengage connector coupling by pulling securing clip - arrow -.
2. Disconnect hose and pipe without the assistance of tools.
3. When assembling, make sure retaining tabs - A - are engaged securely.

1. Before screwing on oil supply line, fill turbocharger with engine oil at filler tube.
2. After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.

If special testing equipment is required during road test, note the following

Rules of cleanliness

When working on turbocharger, carefully observe the following Rules of Cleanliness

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place parts that have been removed on a clean surface and cover. Use lint-free cloths only!
3. Carefully cover over opened components or seal, if repairs are not carried out immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (in tool boxes etc.)

1. Transport and protective packaging and sealing caps are to be removed only immediately prior to installation.
2. During repairs, clean oil from connections and hose ends.
3. When the system is open: Avoid working with compressed air if possible. Do not move vehicle unless absolutely necessary.

Turbocharger Recirculating Valve N249 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. Use only gold-plated terminals when servicing terminals in harness connector of Charge Air Pressure Sensor G31.

Test requirements

1. Fuses for the Engine Control Module (ECM) J623 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. On vehicles with automatic transmission, selector lever in position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Ignition switched off.

Test sequence

1. Remove engine cover - arrows -.

Scheme 973

1. Disconnect the electrical harness connector - 3 - from the Turbocharger Recirculating Valve N249.

Scheme 974

1. Using the Multimeter V.A.G 1526 A or equivalent, check the Turbocharger Recirculating Valve N249 for resistance.

Specified value: 20 to 30 ohms (at approx. 20°C)

If the specification is not obtained

1. Replace Turbocharger Recirculating Valve N249 --> «21 - TURBOCHARGER, G-CHARGER»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

If the specification is obtained

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Check wiring between the Turbocharger Recirculating Valve N249 electrical connector terminal 1 and Engine Component Power Supply Relay J757 terminal 2 for open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory.
2. If necessary, erase the DTC memory.
3. If the DTC memory was erased, generate readiness code.

1. End diagnosis and switch the ignition off.

Wastegate Bypass Regulator Valve N75 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Test requirements

1. Fuses for the Engine Control Module (ECM) J623 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. On vehicles with automatic transmission, selector lever in position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Ignition switched off.

Test sequence

1. Remove engine cover - arrows -.

1. Disconnect electrical harness connector - 2 - at Wastegate Bypass Regulator Valve N75.

1. Using the Multimeter V.A.G 1526 A or equivalent, check the Wastegate Bypass Regulator Valve N75 for resistance.

Specified value: 20 to 25 ohms (at approx. 20°C).

If the specification is not obtained

1. Replace Wastegate Bypass Regulator Valve N75 --> «21 - TURBOCHARGER, G-CHARGER»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

If the specification is obtained

Checking Resistance

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified value: Wire resistance max 1.5 ohms.

If the specified value is not obtained.

1. Repair the wiring connection.

If the specified value is obtained.

1. Check the wiring between the electrical connector terminal 1 and Engine Component Power Supply Relay J757 terminal 2 for an open circuit.

Specified value: Wire resistance max 1.5 ohms.

If the specified value is not obtained.

1. Repair the wiring connection.

If the specified value is obtained.

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Assembly is performed in the reverse order of the removal, note the following

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

1. Charge air system must be properly sealed.
2. Always replace self-locking nuts.
3. Charge air hoses and pipes as well as their connections must be free of oil and grease before re-installation.
4. Do not assemble charge air hoses and pipes with lubricants containing oils, only coat with water (without additives) if necessary.

1. Note installation marks on hoses and components.
2. All hose connections for charge air system are secured by spring-type clamps or by connector couplings.
3. Install only approved clamps for securing hose connections .
4. Spring Type Clip Pliers VAS 5024 A or Hose clamp pliers V.A.G 1921 are recommended for installing spring clamps.

1. For connector couplings, always note the following points

1. Release connector coupling by pulling securing clip - arrow -.
2. Disconnect hose and line without the assistance of tools.
3. When assembling, make sure retaining tabs - A - are engaged securely.

If special testing equipment is required during road test, note the following

When working on turbocharger, carefully observe the following Rules of Cleanliness

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place parts that have been removed on a clean surface and cover. Use lint-free cloths only!
3. Carefully cover over opened components or seal, if repairs are not carried out immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (in tool boxes etc.)

1. Transport and protective packaging and sealing caps are to be removed only immediately prior to installation.
2. During repairs, clean oil from connections and hose ends.
3. When the system is open: Avoid working with compressed air if possible. Do not move vehicle unless absolutely necessary.

Charge Air Pressure Sensor G31 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. Use only gold-plated terminals when servicing terminals in harness connector of Charge Air Pressure Sensor G31.

Test requirements

1. Fuses for the Engine Control Module (ECM) J623 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. On vehicles with automatic transmission, selector lever in position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Ignition switched off.

Test sequence

1. Remove engine cover - arrows -.

Scheme 975

1. Disconnect the electrical harness connector - 2 - from the Charge Air Pressure Sensor G31.
2. Start engine and let it run at idle.

Scheme 976

1. Using the Multimeter V.A.G 1526 A or equivalent, check the Charge Air Pressure Sensor G31 electrical connector terminals 1+3 for voltage.

Specified value: min. 4.5 V

1. Switch ignition off.

If the specification is not obtained

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace Charge Air Pressure Sensor G31 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Motronic fuel injection system, servicing

For all Motronic fuel injection system component locations. Refer to --> 24 - MULTIPORT FUEL INJECTION (MFI)

For all Motronic fuel injection system removal/installation procedures and torque specifications. Refer to --> 24 - MULTIPORT FUEL INJECTION (MFI)

Check the Technical Bulletins for information that may supersede any information included in this article.

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system. Note the following

1. Always switch off ignition before disconnecting or connecting lines of the fuel injection and ignition system, including test leads.
2. During some of the tests, a Diagnostic Trouble Code (DTC) may be recognized and stored by the control module. At the end of all tests and repairs, the DTC memory should be checked and, if necessary, erased. After erasing the DTC memory, a readiness code must be generated for the engine control module.
3. Always switch ignition off before cleaning engine.

Observe the following if test and measuring instruments are required during a test drive

Even minor contaminations can lead to malfunctions in the fuel injection system. When working on the fuel supply/injection system, pay careful attention to the following rules for cleanliness

1. Thoroughly clean all unions and adjacent areas with engine or brake cleaner and dry before disconnecting.
2. Plug open lines and connections immediately with appropriate protective caps.
3. Place removed parts on a clean surface and cover. Use lint-free cloths.
4. Install clean components: Remove replacement parts immediately prior to installation. Do not use parts that have been stored unpackaged (e.g. in tool boxes etc.).

1. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
2. Separated electrical connectors: Protect from dirt and moisture. Make sure connections are dry when reconnecting.

Technical data

Oxygen Sensor (O2S) Heater Z19 for Heated Oxygen Sensor (HO2S) G39 before catalytic converter, checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S) G39 , use only gold-plated terminals.

Test requirements

1. Fuse for Heated Oxygen Sensor (HO2S) G39 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Ignition switched off.

Scheme 977

Test sequence

1. Disconnect the electrical harness connector - 2 - from the Heated Oxygen Sensor (HO2S) -G39-.
2. Using Multimeter V.A.G 1526 A or equivalent, check the Heated Oxygen Sensor (HO2S) G39 electrical connector terminals 3+4 for resistance.

Specified value: 2.5 to 10.0 ohms (at approx. 20°C)

If the specified value is not obtained

1. Replace Heated Oxygen Sensor (HO2S) G39 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

If the specified value is obtained

Scheme 978

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.
2. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connections for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater Z29 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. When servicing terminals in harness connector of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 , use only gold-plated terminals.

Test requirements

1. Fuse for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Ignition switched off.

Test sequence

1. Disconnect the 4-pin electrical harness connector - 1 - from the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130.
2. Using the Multimeter V.A.G 1526 A or equivalent, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 electrical harness connector terminals 1 to 2 for resistance.

Specified resistance: 1.0 to 20.0 ohms (at approx. 20°C)

If the specified value is not obtained

1. Replace Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

If the specified value is obtained

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connections for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Mass Air Flow (MAF) Sensor G70 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow (MAF) Sensor G70.

Test requirements

1. Fuse for Mass Air Flow (MAF) Sensor G70 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Coolant Temperature at least 80°C.
4. Ignition switched off.

Function test

1. Connect the diagnostic tester.
2. Start engine and let it run at idle.
3. Select "Diagnostic mode 1: Check measured values".
4. Select measuring value "PID 16: Air stream amount at Mass Air Flow (MAF) sensor".

1. Check specified value of air flow quantity at Mass Air Flow (MAF) Sensor G70 at idle

1. End diagnosis and switch ignition off.

If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF) Sensor G70

1. Check voltage supply of Mass Air Flow (MAF) Sensor G70 «Checking voltage supply»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg) .

If specified value is not obtained

1. Check wiring of Mass Air Flow (MAF) Sensor G70 «Checking wiring»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__checking-wiring) .

Scheme 979

1. Disconnect the electrical harness connector - 1 - from the Mass Air Flow (MAF) Sensor G70.
2. Start engine and let it run at idle.

Scheme 980

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the Mass Air Flow (MAF) Sensor G70 electrical connector terminal 3 to engine Ground (GND) for voltage.

Specified value: battery voltage

1. Switch ignition off.

If the specified value is not obtained

1. Check wiring between Mass Air Flow (MAF) Sensor G70 electrical connector terminal 3 and Engine Component Power Supply Relay J757 for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

Checking wiring

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace Mass Air Flow (MAF) Sensor G70 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Throttle Valve Control Module J338 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. Use only gold-plated terminals when servicing terminals in harness connector of Throttle Valve Control Module J338.

Test requirements

1. Fuses for Engine Control Module (ECM) J623 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Throttle valve must not be damaged or dirty.
4. Coolant Temperature at least 80°C.

Function

Throttle valve operation occurs via an electric motor (Throttle Drive (for Electronic Power Control (EPC)) G186) in the Throttle Valve Control Module J338 and is operated by the Engine Control Module (ECM) J623 according to the signals supplied by the Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185.

Components of Throttle Valve Control Module J338

1. Throttle Drive (for Electronic Power Control (EPC)) G186
2. Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) G187
3. Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) G188

Function test

1. Connect the diagnostic tester.
2. Switch ignition on.
3. Select "Diagnostic mode 1: Check measured values".
4. Select the measuring value "PID 17: Throttle valve position".

1. Check specified value of throttle valve position (absolute) at idle stop

1. Slowly depress accelerator pedal up to Wide Open Throttle (WOT) stop while observing the percentage display. The percentage display must increase uniformly.
2. Check specified value of throttle valve position (absolute) at Wide Open Throttle (WOT) stop

1. End diagnosis and switch ignition off.

If specified values are not obtained

1. Remove Throttle Valve Control Module J338 far enough so that terminals of connector on Throttle Valve Control Module J338 are reached.

Scheme 981

1. Disconnect the electrical harness connector - 2 - from the Throttle Valve Control Module J338.

Checking resistance

Scheme 982

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the resistance of Throttle Drive (for Electronic Power Control (EPC)) G186 at Throttle Valve Control Module J338 between terminals 3+5.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Replace Throttle Valve Control Module J338 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

If the specification is obtained

1. Check voltage supply of the Throttle Valve Control Module J338 to the Engine Control Module (ECM) J623 «Checking voltage supply and wiring»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__checking-voltage-supply-and-wiring) .
2. Check Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185 --> «Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185 , checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__throttle-position-tp-sensor-g79accelerator-pedal) .

Checking voltage supply and wiring

1. Switch ignition on.

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the voltage of Throttle Drive (for Electronic Power Control (EPC)) G186 at Throttle Valve Control Module J338 between terminals 2+6.

Specified value: at least 4.5 V

1. Switch ignition off.
2. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connections for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Engine Coolant Temperature (ECT) Sensor G62 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

1. Connector test kit V.A.G 1594 C

Note. Use only gold-plated terminals when servicing terminals in harness connector of Engine Coolant Temperature (ECT) Sensor G62.

Test requirements

1. Fuses for Engine Control Module (ECM) J623 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Ignition switched off.
4. Engine cold.

Function test

1. Connect the diagnostic tester.
2. Switch ignition on.
3. Select "Diagnostic mode 1: Check measured values".
4. Select measured value "PID 05: Coolant temperature".

1. Check specified value of coolant temperature

If specified value is not obtained

1. Continue test according to the following table

If specified value is obtained

1. Start engine and let it run at idle.

Temperature value must increase uniformly in increments of 1.0°C.

If the engine shows problems in certain temperature ranges and if the temperature does not climb uniformly, the temperature signal is intermittent.

1. Replace Engine Coolant Temperature (ECT) Sensor G62 --> «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Scheme 983

1. Disconnect the electrical harness connector - 1 - from the Engine Coolant Temperature (ECT) Sensor G62.
2. Using adapter cables from connector test kit V.A.G 1594 C , bridge electrical connector terminals 1 + 2 together and observe indication on display.

If indication jumps to approx. 140.0°C

1. End diagnosis and switch ignition off.
2. Replace Engine Coolant Temperature (ECT) Sensor G62 --> «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

If indication remains at approx. -40.0°C

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.
3. End diagnosis and switch ignition off.

Testing if display approx. 140.0°C

Testing if display approx. -40.0°C

1. Disconnect the electrical harness connector - 1 - from the Engine Coolant Temperature (ECT) Sensor G62.

If indication jumps to approx. -40.0°C

1. End diagnosis and switch ignition off.
2. Replace Engine Coolant Temperature (ECT) Sensor G62 --> «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

1. End diagnosis and switch ignition off.

If indication remains at approx. 140.0°C

Checking wiring

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

Scheme 984

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

Scheme 985

1. Using multimeter V.A.G 1526 B or equivalent, check Engine Coolant Temperature (ECT) Sensor G62 electrical connector terminals 1+2 for resistance.

1. Area A: Resistance values for temperature range 0 to 50°C.
2. Area B: Resistance values for temperature range 50 to 100°C.

Scheme 986

Read-out examples

1. 30°C is in range A and corresponds to a resistance of 1.5 to 2.0 kohms
2. 80°C is in range B and corresponds to a resistance of 275 to 375ohms

If the specification is not obtained

1. Replace Engine Coolant Temperature (ECT) Sensor G62 --> «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

If the specification is obtained

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Intake Air Temperature (IAT) Sensor G42 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

1. Connector test kit V.A.G 1594 C

Note. Use only gold-plated terminals when servicing terminals in harness connector of Intake Air Temperature (IAT) Sensor G42.

Test requirements

1. Fuses of Motronic Engine Control Module (ECM) J220 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Ignition switched off.

Function test

1. Connect the diagnostic tester.
2. Switch ignition on.
3. Select "Diagnostic mode 1: Check measured values".
4. Select measuring value "PID 15: Intake air temperature".

1. Check specified value of intake air temperature

If specified value is not obtained

1. Continue test according to the following table

If specified value is obtained

1. Remove Intake Air Temperature (IAT) Sensor G42 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .
2. Spray Intake Air Temperature (IAT) Sensor G42 with commercially available chilling spray while observing temperature value.

The temperature value must decrease.

1. End diagnosis and switch ignition off.

If intake air temperature does not sink

1. Replace Intake Air Temperature (IAT) Sensor G42 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

Testing if display approx. -40°C or approx. -46°C

1. Disconnect the electrical harness connector - 1 - from Intake Air Temperature (IAT) Sensor G42.

1. Using adapter cables from connector test kit V.A.G 1594 C , connect electrical harness connector terminals 1 + 2 together and observe the indication on display.

If indication jumps to approx. 140°C

1. End diagnosis and switch ignition off.
2. Replace Intake Air Temperature (IAT) Sensor G42 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

If indication remains at approx. -40°C or -46°C

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.
3. End diagnosis and switch ignition off.

Testing if display approx. 140°C

1. Disconnect the electrical harness connector - 1 - from Intake Air Temperature (IAT) Sensor G42.

If indication jumps to approx. -40°C or -46°C

1. End diagnosis and switch ignition off.
2. Replace Intake Air Temperature (IAT) Sensor G42 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

If indication remains at approx. 140°C

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.
3. End diagnosis and switch ignition off.

Checking wiring

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Using multimeter V.A.G 1526 B or equivalent, check Intake Air Temperature (IAT) Sensor G42 electrical connector terminals 1+2 for resistance.

1. Area A: Resistance values for temperature range 0 to 50°C.
2. Area B: Resistance values for temperature range 50 to 100°C.

Read-out examples

1. 30°C is in range A and corresponds to a resistance of 1.5 to 2.0 kohms
2. 80°C is in range B and corresponds to a resistance of 275 to 375ohms

If the specification is not obtained

1. Replace Intake Air Temperature (IAT) Sensor G42 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

If the specification is obtained

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Engine Speed (RPM) Sensor G28 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. Use only gold-plated terminals when servicing terminals in harness connector of Engine Speed (RPM) Sensor G28.

Test requirements

1. Fuses for Engine Control Module (ECM) J623 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Ignition switched off.

Function

The Engine Speed (RPM) Sensor G28 detects RPM and reference marks. Without an engine speed signal, the engine will not start. If the engine speed signal fails while the engine is running, the engine will stop immediately.

Function test

1. Connect the diagnostic tester.
2. Start engine and let it run at idle.
3. Select "Diagnostic mode 1: Check measured values".
4. Select the measuring value "PID 12: Engine rotations per minute (RPM)".

1. Check specified value

If specified value is not obtained

1. End diagnosis and switch ignition off.
2. Check resistance of Engine Speed (RPM) Sensor G28 and wires

Test sequence

Scheme 987

1. Disconnect the electrical harness connector - 3 - from the Engine Speed (RPM) Sensor G28.

Scheme 988

1. Using multimeter V.A.G 1526 B or equivalent, check Engine Speed (RPM) Sensor G28 electrical connector terminals 2+3 for resistance.

Specified value: 730 to 1000 ohms (at approx. 20°C)

1. Using multimeter V.A.G 1526 B or equivalent, check Engine Speed (RPM) Sensor G28 for short circuit between terminals 1 + 2 as well as 1 + 3.

Specified value: 0 ohms

If specification is not obtained

1. Replace Engine Speed (RPM) Sensor G28 --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

If specification is obtained

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

Wires OK

1. Remove Engine Speed (RPM) Sensor G28 and check sensor wheel for proper seating, damage and run-out --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

If the specification is obtained

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Intake Flap Motor V157/Intake Manifold Runner Position Sensor G336 , checking

Test requirements

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

1. Fuses of Motronic Engine Control Module (ECM) J220 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Ignition switched off.

Test sequence

1. Remove engine cover - arrows -.

Scheme 989

1. Disconnect the electrical harness connector - arrow - from the Intake Flap Motor V157/Intake Manifold Runner Position Sensor G336.
2. Switch ignition on.

1. Using multimeter V.A.G 1526 B or equivalent, check electrical connector terminals 1+3 for voltage.
2. Specified value: about 5 V
3. Switch ignition off.

If the specified value is not obtained

1. Replace Intake Flap Motor V157/Intake Manifold Runner Position Sensor G336 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

If the specified value is obtained

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.
2. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Fuel Pressure Sensor G247 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Test requirements

1. Fuel Pump (FP) Control Module J538 OK.
2. The fuses for the engine electronics OK..
3. The fuel filter OK.
4. The parking brake engaged.

1. The battery voltage at least 12.5 V.
2. The selector lever of automatic transmission in position "P" or "N".
3. All electrical consumers switched off (radiator fan must NOT run during test).
4. A/C switched off.

1. The fuel tank at least 1 / 4 filled.
2. The ignition switched off.

Procedure

1. Remove engine cover - arrows -.

Checking voltage

Scheme 990

1. Disconnect the electrical harness connector - 3 - for the Fuel Pressure Sensor G247.
2. Switch the ignition on.

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the Fuel Pressure Sensor G247 electrical harness connector for voltage.

1. Switch the ignition off.

If specified value is obtained

1. Replace the Fuel Pressure Sensor G247 : --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

If the specified value was not obtained

Checking wiring connections

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Assembly is performed in the reverse order of removal.

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Low Fuel Pressure Sensor G410 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Test requirements

1. Fuel Pump (FP) Control Module J538 OK; check.
2. The fuel filter OK.
3. The fuses for the engine electronics OK..
4. The parking brake engaged.

1. The battery voltage at least 12.5 V.
2. The selector lever of automatic transmission in position "P" or "N".
3. All electrical consumers switched off (radiator fan must NOT run during test).
4. A/C switched off.

1. The fuel tank at least 1 / 4 filled.
2. The ignition switched off.

Procedure

1. Remove engine cover - arrows -.

Checking voltage

Scheme 991

1. Disconnect the electrical harness connector - 2 - from the Low Fuel Pressure Sensor G410.
2. Switch the ignition on.

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the electrical harness connector for voltage.

1. Switch the ignition off.

If specified value is obtained

1. Replace the Low Fuel Pressure Sensor G410 , note the following

Note. The 2.0L 4-Cyl. 4V (BPG) engine is equipped with two different Low Fuel Pressure Sensors G410 designs. One design is integrated into the high pressure fuel pump and must be replaced as a complete assembly. --> 24 - MULTIPORT FUEL INJECTION (MFI) . The second design is not integrated into the high pressure fuel pump and may be replaced separately.

If the specified value was not obtained

Checking wiring connections

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Assembly is performed in the reverse order of removal.

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Fuel Metering Valve N290 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Test requirements

1. Fuses for Engine Control Module (ECM) J623 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Ignition switched off.

Procedure

1. Remove engine cover - arrows -.

Test sequence

Scheme 992

1. Disconnect the electrical harness connector - 2 - from the Fuel Metering Valve N290.

Scheme 993

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the Fuel Metering Valve N290 for resistance.
2. Specified value: 25 to 35 ohms (at approx. 20°C)

If the specified value is not obtained

1. Replace Fuel Metering Valve N290 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

If the specified value is obtained

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the electrical connector terminal 1 to Ground (GND) for voltage.

Specified value: approx. battery voltage

If the specified value is not obtained

1. Check wiring from the Fuel Metering Valve N290 electrical connector terminal 1 to the Engine Component Power Supply Relay J757 terminal 2 for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Fuel pressure and residual pressure before high pressure pump , checking

Special tools, testers and auxiliary items required

Scheme 994

1. Fuel Injection Pressure Gauge Set V.A.G. 1318 with Adapter V.A.G. 1318/6 and Adapter V.A.G. 1318/7.

Scheme 995

1. Remote control V.A.G 1348/3 A with adapter cable V.A.G 1348/3-3

Test requirements

1. Fuel Pump (FP) Control Module J538 OK; check --> «20 - FUEL SUPPLY SYSTEM»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .
2. The fuel filter OK.
3. The parking brake engaged.
4. Battery voltage at least 12.5 V.

1. The selector lever of automatic transmission in position "P" or "N".
2. All electrical consumers switched off (radiator fan must NOT run during test).
3. A/C switched off.
4. The fuel tank at least 1 / 4 filled.

1. The ignition switched off.

Checking system pressure

1. Remove the rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Remove the cover for the right locking flange - arrows -.

1. Carefully release and disconnect the electrical harness connector - arrow - at the locking flange.

Scheme 996

1. Connect the remote control connection V.A.G 1348/3 A with connection V.A.G 1348/3-3 to contact - 5 - using an adapter cable from the connector test set V.A.G 1594 C.
2. Using insulating tape, tape over the second contact of connection V.A.G 1348/3-3 to prevent a short circuit - arrow -.
3. Route the switch of the remote control V.A.G 1348/3 A forward into the engine compartment.
4. Connect the alligator clip to ground (GND) point in the engine compartment.

1. Connect the contact - 1 - to battery positive terminal (B+) using a self-made adapter cable.

Note. For safety reasons, install a fuse - A - in the cable.

1. Remove engine cover - arrows -.

1. Disconnect the fuel line - arrow -.

1. Connect the pressure gauge V.A.G 1318 to the fuel line using adapter V.A.G 1318/11 and V.A.G 1318/12.
2. Connect the extension hose - arrow - to the pressure gauge and hold it in a measuring container.
3. Open the pressure gauge shut-off valve. The lever points in direction of flow.
4. Bleed the fuel system, by briefly pressing the remote control.

Scheme 997

1. Close the pressure gauge shut-off valve. The lever is perpendicular to the direction of flow - arrow -.
2. Hold the remote control switch until no more pressure increase is observed on the fuel pressure gauge.

1. Specification: approx. 6 bar positive pressure

If the specification is not obtained

1. Check the delivery rate of the fuel pump --> «20 - FUEL SUPPLY SYSTEM»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Checking residual pressure

1. Check for leaks and residual pressure by observing the pressure loss on the pressure gauge.

1. After 10 minutes there must be a residual pressure of at least 3.75 bar.

The holding pressure drops below 3.75 bar

1. Check the connection between the fuel pressure gauge and the fuel line for leaks.
2. Check the pressure gauge for leaks.
3. Check the fuel lines and their connections for leaks.
4. Replace the fuel filter with integrated fuel pressure regulator --> «20 - FUEL SUPPLY SYSTEM»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

1. Replace the fuel pump --> «20 - FUEL SUPPLY SYSTEM»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Assembly is performed in the reverse order of removal. Note the following

Note. Before disconnecting the pressure gauge, release the fuel pressure by opening the shut-off valve. Hold a container under the connection.

Torque specifications

Fuel Injectors N30, N31, N32, N33 , checking

This procedure is used to diagnose all fuel injectors.

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

1. Voltage Tester VAG1527B or equivalent.

Electrical test

Test requirements

1. Fuses for Fuel Injectors N30, N31, N32, N33 OK.
2. Engine Speed (RPM) Sensor G28 OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.

1. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
2. A/C switched off.
3. Ground (GND) connections between engine/transmission/chassis OK.
4. Ignition switched off.

Procedure

1. Remove engine cover - arrows -.
2. Disconnect the electrical harness connectors on Fuel Injectors N30, N31, N32, N33.

Checking resistances

Scheme 998

1. Using multimeter V.A.G 1526 B or equivalent, check Fuel Injector electrical connector terminal 1+2 for resistance

Specified value: 12.0 to 20.0 ohms (at approx. 20°C)

If the specification is not obtained

1. Replace the malfunctioning fuel Injector --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

Checking activation and wires

Scheme 999

1. Using Voltage Tester VAG1527B or equivalent, check the fuel Injector electrical connector for voltage.
2. Operate starter and test activation for Fuel Injector.

LED should flicker.

1. Switch ignition off.

If LED does not flicker

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

Scheme 1000

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specified value is not obtained

1. Repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Assembly is performed in the reverse order of removal, note the following

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch ignition off.

Checking intake system for leaks (false air)

Special tools, testers and auxiliary items required

1. Engine Leak Detection Spray G 001 800 A1.
2. Engine leak detection spray G 001 800 A1.

Note. Vacuum in the intake system sucks in the leak detection spray with false air. Leak detection spray decreases ignition quality of the fuel mixture. This causes a reduction in engine speed and a sharp increase of CO content. It is absolutely necessary to follow the safety precautions listed on the can.

Test requirements

1. Coolant temperature at least 80 C°.
2. The parking brake engaged.
3. The selector lever of automatic transmission in position "P" or "N".
4. The ignition switched off.

Test sequence

1. Connect the diagnostic tester.
2. Start the engine and let run at idle.
3. Select "Mode 1: Checking measured values".
4. Select the following measured values

1. Spray the intake system parts with engine leak detection spray in a systematic manner.

If the engine speed drops or if the short-term gasoline-air ratio changes

1. End diagnosis and switch the ignition off.
2. Check the sprayed part of intake system for leaks, and repair the malfunction.

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Heated Oxygen Sensor (HO2S) G39 and oxygen sensor regulation before catalytic converter, checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S) G39 , use only gold-plated terminals.

Test requirements

1. Fuse for Heated Oxygen Sensor (HO2S) G39 OK.
2. Oxygen Sensor (O2S) Heater Z19 before catalytic converter OK, checking --> «Oxygen Sensor (O2S) Heater Z19 for Heated Oxygen Sensor (HO2S) G39 before catalytic converter, checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__oxygen-sensor-o2s-heater-z19-for) .
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Exhaust system between catalytic converter and cylinder head properly sealed.
4. Coolant Temperature at least 80°C.

Function test

1. Connect the diagnostic tester.
2. Start engine and let it run at idle.
3. Select "Diagnostic mode 6: Check test results of components that are not continuously monitored".
4. Select "Test-ID 01: Oxygen sensor monitoring before catalytic converter".

1. Select "Test-ID 131: Dynamic test" and check whether specified values are obtained.

1. End diagnosis and switch ignition off.

If specified values are not obtained

1. Check Heated Oxygen Sensor (HO2S) G39 wiring.

Testing of oxygen sensor wires

1. Disconnect the 6-pin electrical harness connector - 2 - from the Heated Oxygen Sensor (HO2S) -G39-.
2. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connections for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in wiring

1. Replace Heated Oxygen Sensor (HO2S) -G39- --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

Final procedures

After repair work, the following work steps must be performed in the following sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch ignition off.

Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and oxygen sensor regulation behind catalytic converter, checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. When servicing terminals in harness connector of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 , use only gold-plated terminals.

Test requirements

1. Fuse for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 OK.
2. Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater Z29 OK, checking --> «Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater Z29 , checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__oxygen-sensor-o2s-1-behind-three) .
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.

1. Vehicles with automatic transmission, selector lever in position "P" or "N".
2. A/C switched off.
3. Ground (GND) connections between engine/transmission/chassis OK.
4. Exhaust system between catalytic converter and cylinder head properly sealed.

1. Coolant Temperature at least 80°C.

Function test

1. Connect the diagnostic tester.
2. Start engine and let it run at idle.
3. Select "Diagnostic mode 6: Check test results of components that are not continuously monitored".
4. Select "Test-ID 02: Oxygen sensor monitoring behind catalytic converter".

1. Select following Test-ID.
2. Check specified values at idle.

If specified values are obtained

1. End diagnosis and switch ignition off.

If specified values are not obtained

1. End diagnosis and let engine continue to run at idle.
2. Check primary voltage.

Checking primary voltage

1. Disconnect the 4-pin electrical harness connector - 1 - from the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130.

Scheme 1001

1. Using the Multimeter V.A.G 1526 A or equivalent, check the electrical harness connector terminals 3 to 4 for voltage.

Specified value: 0.400 to 0.500 Volts

1. Switch ignition off.

If specified value is not obtained

1. Replace Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

If specified value is obtained

Testing of oxygen sensor wires

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connections for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

After repair work, the following work steps must be performed in the following sequence

Final procedures

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch ignition off.

Engine Control Module (ECM) J623 voltage supply, checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Test requirements

1. The fuse for the engine electronics OK.
2. The Ground (GND) connections at the engine and transmission OK.
3. The battery voltage at least 12 V.
4. The generator OK.

1. The ignition is switched off.

Test sequence

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.
2. Switch the ignition on.
3. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connections for voltage.

Specified value: approx. battery voltage.

1. Switch the ignition off.
2. Using the Multimeter V.A.G. 1526 A or equivalent, check the following wiring connections for voltage.

1. Switch ignition on.

Specified value: approx. battery voltage.

1. Switch the ignition off.

If the specified values are not obtained

1. Using the Multimeter V.A.G. 1526 A or equivalent, check the wiring connections for an open circuit.

Specified value: Wire resistance max 1.5 ohms.

1. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Check the Motronic Engine Control Module (ECM) Power Supply Relay J271 --> «Motronic Engine Control Module (ECM) Power Supply Relay J271 , checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__motronic-engine-control-module-ecm-power) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Motronic Engine Control Module (ECM) Power Supply Relay J271 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. The Motronic Engine Control Module (ECM) Power Supply Relay J271 supplies voltage to the ignition coils with power output stages as well as the Engine Control Module (ECM) J623 at pin 3 and a few additional components. With the ignition switched on, 12 Volts must be present at the respective ignition coil connector, terminal 1.

Test requirement

1. The fuse for the engine electronics OK..
2. Battery voltage at least 12.5 V.
3. The Ground (GND) connections at the engine and transmission OK.
4. The ignition is switched off.

Test sequence

1. Remove the rubber seal in the direction of the - arrow -.

Scheme 1002

1. Remove the plenum chamber cover - 1 -.
2. Using a screwdriver, remove wiper arm caps - 3 - from wiper arms.
3. Loosen wiper arm nuts - 4 - several turns.
4. Loosen wiper arms - 2 - from wiper axle by tilting slightly.

1. Remove wiper arm nuts completely and remove wiper arms.

Scheme 1003

1. Remove securing clips - 1 - and cowl - 5 -.

Scheme 1004

1. Remove the screws - arrows - and cover from the E-Box in the plenum chamber.

Scheme 1005

1. Using a screwdriver, remove the retainer bar - arrow - and Engine Control Module (ECM) J623 and position aside.

Scheme 1006

1. Remove the Motronic Engine Control Module (ECM) Power Supply Relay J271 - 2 - from the E-Box.
2. Remove the Motronic Engine Control Module (ECM) Power Supply Relay J271 - 2 - from the E-box.

Scheme 1007

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.
2. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

Checking voltage supply

1. Using the Multimeter V.A.G 1526 A or equivalent, check the following wiring connections for voltage.

Specified value: approx. battery voltage.

If the specified value is not obtained

1. Using the Multimeter V.A.G 1526 A or equivalent, check the wiring connections for an open circuit.

Specified resistance 1.5 ohms max.

If no malfunctions are found in the wiring

Checking wiring connection

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are detected

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Assembly is performed in the reverse order of the removal, note the following

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Engine Control Module (ECM) J623 , replacing

Special tools, testers and auxiliary items required

Scheme 1008

1. Heat gun - 1 - (from the wiring harness repair kit VAS 1978)
2. Nozzle attachment - 2 - (also from wiring harness repair kit VAS 1978)
3. Commercially available locking pliers (vise grips)

Note. When connector is disconnected from the Engine Control Module (ECM), adaptation values are erased and content of DTC memory remains intact.

Removing

1. Remove the rubber seal in the direction of the - arrow -.

1. Remove the plenum chamber cover - 1 -.
2. Using a screwdriver, remove wiper arm caps - 3 - from wiper arms.
3. Loosen wiper arm nuts - 4 - several turns.
4. Loosen wiper arms - 2 - from wiper axle by tilting slightly.

1. Remove wiper arm nuts completely and remove wiper arms.

1. Remove securing clips - 1 - and cowl - 5 -.

1. Remove the screws - arrows - and cover from the E-Box in the plenum chamber.

1. Using a screwdriver, remove the retainer bar - arrow - and Engine Control Module (ECM) J623 from the E-box.

Note. The threads of shear bolts (that are not screwed into ECM) are coated with a locking compound. For this reason, the threads must be heated with the heat gun to remove both bolts. The threads of both shear bolts (that are screwed into ECM) are not coated with a locking compound. The threads in the ECM housing must not be heated and do not require to be heated (unintentional heating of ECM).

Scheme 1009

1. Using heat gun, direct the heat gun nozzle at shear bolt of retaining tab for approx. 20 to 25 seconds.

Scheme 1010

1. Using locking pliers, remove shear bolt.

The procedure for second shear bolt is exactly the same.

Scheme 1011

Remove the protective housing from the Engine Control Module (ECM) J623.

Scheme 1012

1. Disengage the electrical connector retainers - arrows - and disconnect electrical connectors - 1 and 2 - from Engine Control Module (ECM) J623.
2. Remove old Engine Control Module (ECM) J623.

Installing

Installation is in reverse order of removal, the Engine Control Module (ECM) J623 must be installed with protective housing. New shear bolts must be used.

After installing new Engine Control Module (ECM), the following work steps must be performed

1. The New Engine Control Module (ECM) J623 and immobilizer must be activated.

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Speed signal, checking

Test requirement

1. Function and display of speedometer OK.

1. Connect the diagnostic tester.
2. Start the engine and let run at idle.
3. Select "Diagnostic mode 1: Obtain data".
4. Select the measured value "PID 13: Vehicle speed".

1. Perform a road test, and have the 2nd person observe the indication on the display.
2. Check the specified value of the vehicle speed

1. End the diagnosis and switch ignition off.

If no speed is displayed

The speed signal is transferred from the Engine Control Module (ECM) J623 to the instrument cluster via wire connection or via CAN-Bus, depending on version.

1. Check the wiring connections.
2. Check the terminal resistance for the CAN-Bus --> «Terminal resistance for Can-Bus, checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__terminal-resistance-for-can-bus-checking) .

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and the switch ignition off.

Terminal resistance for Can-Bus, checking

The Engine Control Module (ECM) J623 communicates with all the databus capable control modules via a CAN databus.

These databus capable control modules are connected via two data bus wires which are twisted together (CAN_High and CAN_Low), and exchange information (messages). Missing information on the databus is recognized as a malfunction and stored.

Trouble-free operation of the CAN-bus requires that it have a terminal resistance. The central terminal resistor is located in the Engine Control Module (ECM) J623.

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Test requirement

1. Ignition switched off.

Test sequence

1. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The wiring harness is not connected.
2. Check the central termination resistor in the Engine Control Module (ECM) J623.
3. Using Multimeter V.A.G 1526 A or equivalent, check the following wiring connection between terminal 58 and 60 of the Test box V.A.G. 1598/31 for resistance.

Specified resistance: 60.......72 ohms

If the specification is exceeded or not met

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

If the specified value is obtained

1. Disconnect the Test Box 105 Pin VAG1598/42 from the Engine Control Module (ECM) J623 wiring harness.
2. Connect the Test Box 105 Pin VAG1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.
3. Using Multimeter V.A.G 1526 A or equivalent, check the following wiring connection between terminals 58 and 60 of the Test Box 105 Pin VAG1598/42 for resistance.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch the ignition off.

Exhaust system

For all Exhaust System, Emission control component locations. Refer to --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS

For all Exhaust System, Emission control removal/installation procedures and torque specifications. Refer to --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS

Check the Technical Bulletins for information that may supersede any information included in this article.

Three Way Catalytic Converter (TWC), checking

Function test

1. Connect the diagnostic tester.
2. Start engine and let it run at idle.
3. Select "Diagnostic mode 6: Check test results of components that are not continuously monitored".
4. Select "Test-ID 33 ($21): Catalytic converter monitoring" «Test-ID 33 ($21): Catalytic Converter Monitoring»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__test-id-33-21-catalytic-converter-monitoring) .

1. Select Test-ID 132 ($84).
2. Check specified values at idle.

1. End diagnosis and switch ignition off.

If specified values are exceeded

1. Replace front exhaust pipe with catalytic converter --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Assembly is performed in the reverse order of removal, note the following

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch ignition off.

Ignition system, servicing

For all Ignition/Glow plug system component locations. Refer to --> 28 - IGNITION/GLOW PLUG SYSTEM

For all Ignition/Glow plug system removal/installation procedures and torque specifications. Refer to --> 28 - IGNITION/GLOW PLUG SYSTEM

Check the Technical Bulletins for information that may supersede any information included in this article.

Ignition Coil with Power Output Stage N70, N127, N291, N292 , checking

The following procedure is used to diagnose all ignition coils with power output stages.

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

1. Voltage Tester VAG1527B or equivalent.

Note. The ignition coils and power output stages are one component and cannot be replaced individually.

Test requirement

The fuses for the engine electronics OK..

Procedure

Check for a misfiring cylinder as follows

1. Compare the spark plugs of all the cylinders to each other. Check the electrodes for carbon fouling.

If a faulty cylinder is recognized

1. Switch the spark plug from the faulty cylinder with one from another cylinder.

If the malfunction follows the spark plug

1. Replace the spark plug.

If the malfunction remains at the original cylinder

1. Switch the ignition coil from the faulty cylinder with one from another cylinder.

If the malfunction follows the ignition coil

1. Replace the ignition coil.

Electrical harness removal

1. Remove engine cover - arrows -.

Scheme 1013

1. Remove the screws - 1 - retaining the electrical harness to the valve cover.

Scheme 1014

1. Disconnect the electrical harness connectors - arrows - from the ignition coils

Checking voltage supply

1. Using the Voltage Tester VAG1527B or equivalent, check the following wiring connections for voltage.

The LED must light up.

If the LED does not light up

Checking resistance

1. Using the Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

1. If necessary, repair the wiring connection.

If the LED lights up

1. Switch the ignition on.
2. Using the Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for voltage.

Specified value: approx. battery voltage

1. Switch the ignition off.

If the specified value is obtained

Checking activation of power output stages

1. Remove the rubber seal in the direction of the - arrow -.

1. Remove the plenum chamber cover - 1 -.
2. Using a screwdriver, remove wiper arm caps - 3 - from wiper arms.
3. Loosen wiper arm nuts - 4 - several turns.
4. Loosen wiper arms - 2 - from wiper axle by tilting slightly.

1. Remove wiper arm nuts completely and remove wiper arms.

1. Remove securing clips - 1 - and cowl - 5 -.

1. Remove the screws - arrows - and cover from the E-Box in the plenum chamber.

1. Using a screwdriver, remove the retainer bar - arrow - and Engine Control Module (ECM) J623 and position aside.

1. Remove the Motronic Engine Control Module (ECM) Power Supply Relay J271 - 2 - from the E-Box.

1. Using the Multimeter V.A.G 1526 A or equivalent, check the wiring connection from the Motronic Engine Control Module (ECM) Power Supply Relay J271 carrier position 2, terminal 2 to the ignition coil wiring harness electrical connector terminal 1 for an open circuit.

Specified resistance 1.5 ohms max.

If the specified value is not obtained

1. Repair the wiring connection.

If no malfunctions are found in the wiring

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the faulty ignition coil. --> «28 - IGNITION/GLOW PLUG SYSTEM»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

Assembly is performed in the reverse order of removal, note the following

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch ignition off.

Camshaft Adjustment Valve 1 N205 , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Test requirements

1. Fuse for Camshaft Adjustment Valve 1 N205 OK.
2. Motronic Engine Control Module (ECM) Power Supply Relay J271 OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.

1. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
2. A/C switched off.
3. Ground (GND) connections between engine/transmission/chassis OK.
4. Ignition switched off.

Test sequence

1. Remove engine cover - arrows -.

1. Disconnect the electrical harness connector - 1 - from Camshaft Adjustment Valve 1 N205.
2. Using the Multimeter V.A.G 1526 A or equivalent, check the Camshaft Adjustment Valve 1 N205 for resistance.

Specified value: 5.0 to 8.0 ohms (at approx. 20°C)

If the specification is not obtained

1. Replace Camshaft Adjustment Valve 1 N205 --> «15 - ENGINE - CYLINDER HEAD, VALVETRAIN»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

If the specification is obtained

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

Scheme 1015

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for an open circuit.

Specified resistance 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Assembly is performed in the reverse order of removal, note the following

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch ignition off.

Knock Sensor , checking

This procedure is used to diagnose Knock Sensor (KS) 1 G61 and Knock Sensor (KS) 2 G66.

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. Cylinders 1, 2 are monitored by Knock sensor (KS) 1 -G61-. Cylinders 3,4 are monitored by Knock sensor (KS) 2 -G66-. Knock sensors themselves cannot be checked electrically. When servicing terminals in the harness connector of knock sensors, use only gold-plated terminals. For the knock sensors to function properly, it is important that the tightening torque be exactly 20 Nm. Contact surfaces between Knock Sensor (KS) 1 G61 and Knock Sensor (KS) 2 G66 and cylinder block must be free of corrosion, dirt and grease.

Test requirements

1. Mounting bolt of Knock Sensor (KS) 1 G61/Knock Sensor (KS) 2 G66 tightened to 20 Nm.
2. Fuses for Engine Control Module (ECM) J623 OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.

1. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
2. A/C switched off.
3. Ground (GND) connections between engine/transmission/chassis OK.
4. Ignition switched off.

Test sequence

1. Remove engine cover - arrows -.

Note. The knock sensor electrical connectors can be identified by color. Knock Sensor (KS) 1 -G61- (Bank 1) is green. Knock Sensor (KS) 2 -G66- (Bank 2) is gray.

1. Disconnect the electrical harness connector from Knock Sensor (KS) 1 G61 - 1 - or Knock Sensor (KS) 2 G66 - 2 -.
2. Using the Multimeter V.A.G 1526 A or equivalent, check Knock Sensor (KS) 1 G61 or Knock Sensor (KS) 2 G66 electrical connector terminals 1+2 for resistance for a short to each other.

Specified value: 0 ohms (No Continuity).

If the specification is not obtained

1. Replace respective Knock Sensor (KS) 1 G61/Knock Sensor (KS) 2 G66 --> «15 - ENGINE - CYLINDER HEAD, VALVETRAIN»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

If the specification is obtained

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

Scheme 1016

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connections for an open circuit.

Specified resistance 1.5 ohms max.

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Assembly is performed in the reverse order of removal, note the following

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch ignition off.

Camshaft Position (CMP) Sensors , checking

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 or equivalent.
2. Test Box 105 Pin VAG1598/42.
3. Adapter Lead Vag1598/39 VAG1598/39.
4. Adapter cable V.A.G 1598/39-1.

Note. Use only gold-plated terminals when servicing terminals in harness connector of Camshaft Position (CMP) Sensor G40.

Test requirements

1. Fuses for Engine Control Module (ECM) J623 OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".

1. A/C switched off.
2. Ground (GND) connections between engine/transmission/chassis OK.
3. Ignition switched off.

Checking activation

1. Remove engine cover - arrows -.
2. Disconnect the electrical harness connector - 1 - at Camshaft Position (CMP) Sensor G40.
3. Using the Voltage Tester VAG1527B or equivalent, check for voltage between terminal 1 and terminal 2 with the electrical harness connector connected to Camshaft Position (CMP) Sensor G40.
4. Operate the starter briefly.

The LED must blink.

Note. Voltage testers do not go out completely during low current pick-up between activations by the ECM, but rather continue to glow a little and then get significantly brighter during activation.

1. Switch ignition off.

If the LED does not blink

Checking voltage supply

1. Using the Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for voltage.

1. Switch the ignition on.

Specified value: about 5 V.

1. Switch the ignition off.

Checking signal wire

1. Using the Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for voltage.

1. Switch the ignition on.

Specified value: approx. battery voltage.

1. Switch the ignition off.

Checking Ground (GND)

1. Using the Multimeter V.A.G 1526 A or equivalent, check the following wiring connection for voltage.

Specified value: about 10 V.

If the specified values are obtained

1. Replace Camshaft Position (CMP) Sensor G40 --> «28 - IGNITION/GLOW PLUG SYSTEM»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) .

If the specified values are not obtained

Checking resistance

1. Connect the test box 1598/42 to the wiring harness of the Engine Control Module (ECM) J623. --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) . The ECM is not connected.

1. Using the Test Box 105 Pin VAG1598/42 and Multimeter V.A.G 1526 A or equivalent, check the following wiring connections for an open circuit.

1. Camshaft Position (CMP) Sensor G40 (bank 1).

Specified resistance 1.5 ohms max.

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

1. Replace the Engine Control Module (ECM) J623 --> «Engine Control Module (ECM) J623 , replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__engine-control-module-ecm-j623) .

Assembly is performed in the reverse order of removal, note the following

Final procedures

After repair work, the following work steps must be performed in the mentioned sequence

1. Check the DTC memory..
2. If necessary, erase the DTC memory..
3. If the DTC memory was erased, generate readiness code..

1. End diagnosis and switch ignition off.

Electrical components for regulating transmission O9L, checking

For all Automatic Transmission- Gears, Hydraulic controls component locations. Refer to --> 38 GEARS, CONTROL

For all Automatic Transmission- Gears, Hydraulic controls removal/installation procedures and torque specifications. Refer to --> 38 GEARS, CONTROL

Check the Technical Bulletins for information that may supersede any information included in this article.

Safety precautions

Note. Certainly you have received an electrical shock once before when touching something made out of metal. The reason for this is the electrostatic charge of the human body. This charge can lead to functional problems by touching the electrical components of the transmission and selector lever mechanism. Touch a grounded object, e.g. a water pipe or a lifting platform, before working on the electrical components! Do not make direct contact on connector terminals of the Mechatronic unit! The batteries must only be disconnected and connected with the ignition switched off, since the Mechatronic unit can otherwise be damaged.

If special testing equipment is required during road test, note the following

1. Test equipment must always be secured to the rear seat and operated from there by a second person.

If test and measuring equipment is operated from the passenger seat, the person seated there could be injured in the event of an accident involving deployment of the passenger-side airbag.

Note. For the electric components to work properly, a voltage of at least 12.5 V is required. Transmission Control Module (TCM) is equipped with On Board Diagnostic (OBD). It is possible that the control module will recognize a malfunction and store a DTC during some tests. Therefore the following work steps must be performed in the mentioned sequence after ending all tests and repairs.

1. Check the DTC memory..
2. If necessary, erase DTC memory of the Transmission Control Module (TCM) J217..
3. Generate readiness code..

Multi-Function Transmission Range (TR) Switch, checking

Note. The Multi-Function Transmission Range (TR) Switch F125 is a component of the Mechatronic unit in the transmission.

Requirements

1. Control Module with indicator unit in the Instrument Cluster Control Module J285 must be OK.
2. The battery voltage must be at least 12.5 Volts.
3. All electrical consumers must be switched off.
4. The parking brake must be engaged.

1. The elector lever must be in the "P" position.
2. The Ground (GND) connections to transmission must be OK.

Test sequence

1. Switch the ignition on.
2. Depress the brake pedal and maintain depressed.
3. Shift the selector lever into all positions.

The selector lever position must correspond to the display of the Control Module with the indicator unit in the Instrument Cluster Control Module J285.

1. Switch the ignition off.

Scheme 1017

If the selector lever position does not correspond to the display of the Control Module with indicator unit in the Instrument Cluster Control Module J285

1. Disconnect the electrical connector in the - direction of the arrow - and remove it from the Transmission Control Module (TCM) J217.
2. Observe safety precautions.
3. Check the electrical harness connector for contact corrosion and ingress of water.

If the electrical harness connector is not OK

1. Repair the malfunction and repeat the test sequence.

If the electrical harness connector is OK

1. Check the wiring according to the wiring diagram

If no malfunctions are found in the wiring

1. Replace the Mechatronic unit in the transmission: --> «38 GEARS, CONTROL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) .

Note. The Transmission Control Module (TCM) J217 is a component of the Mechatronic unit and cannot be replaced separately.

Final procedures

1. Check the DTC memory..
2. If necessary, erase DTC memory of the Transmission Control Module (TCM) J217..
3. Generate readiness code..

Sensor for transmission RPM, checking

Note. The Transmission Input Speed (RPM) Sensor G182 is a component of the Mechatronic unit in the transmission.

Requirements

1. The battery voltage must be at least 12.5 Volts.
2. All electrical consumers must be switched off.
3. The parking brake must be engaged.
4. The elector lever must be in the "P" position.

1. The Ground (GND) connections to transmission must be OK.

Test sequence

1. Disconnect the electrical connector in the - direction of the arrow - and remove it from the Transmission Control Module (TCM) J217.
2. Observe safety precautions.
3. Check the electrical harness connector for contact corrosion and ingress of water.

If the electrical harness connector is not OK

1. Repair the malfunction.

If the electrical harness connector is OK

1. Check the wiring according to the wiring diagram

If no malfunctions are found in the wiring

1. Replace the Mechatronic unit in the transmission: --> «38 GEARS, CONTROL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) .

Note. The Transmission Input Speed (RPM) Sensor G182 is a component of the Mechatronic unit and cannot be replaced separately.

Final procedures

1. Check the DTC memory..
2. If necessary, erase DTC memory of the Transmission Control Module (TCM) J217..
3. Generate readiness code..

Sensor for transmission output RPM, checking

Note. The Transmission Output Speed (RPM) Sensor G195 is a component of the Mechatronic unit in the transmission.

Requirements

1. The battery voltage must be at least 12.5 Volts.
2. All electrical consumers must be switched off.
3. The parking brake must be engaged.
4. The elector lever must be in the "P" position.

1. The Ground (GND) connections to transmission must be OK.

Test sequence

1. Disconnect the electrical connector in the - direction of the arrow - and remove it from the Transmission Control Module (TCM) J217.
2. Observe safety precautions.
3. Check the electrical harness connector for contact corrosion and ingress of water.

If the electrical harness connector is not OK

1. Repair the malfunction.

If the electrical harness connector is OK

1. Check the wiring according to the wiring diagram

If no malfunctions are found in the wiring

1. Replace the Mechatronic unit in the transmission: --> «38 GEARS, CONTROL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) .

Note. The Transmission Output Speed (RPM) Sensor G195 is a component of the Mechatronic unit and cannot be replaced separately.

Final procedures

1. Check the DTC memory..
2. If necessary, erase DTC memory of the Transmission Control Module (TCM) J217..
3. Generate readiness code..

Transmission Fluid Temperature Sensor, checking

Note. The Transmission Fluid Temperature Sensor G93 is a component of the Mechatronic unit in the transmission.

Requirements

1. The battery voltage must be at least 12.5 Volts.
2. All electrical consumers must be switched off.
3. The parking brake must be engaged.
4. The elector lever must be in the "P" position.

1. The Ground (GND) connections to transmission must be OK.

Test sequence

1. Disconnect the electrical connector in the - direction of the arrow - and remove it from the Transmission Control Module (TCM) J217.
2. Observe safety precautions.
3. Check the electrical harness connector for contact corrosion and ingress of water.

If the electrical harness connector is not OK

1. Repair the malfunction.

If the electrical harness connector is OK

1. Check the wiring according to the wiring diagram

If no malfunctions are found in the wiring

1. Replace the Mechatronic unit in the transmission: --> «38 GEARS, CONTROL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) .

Note. The Transmission Fluid Temperature Sensor G93 is a component of the Mechatronic unit and cannot be replaced separately.

Final procedures

1. Check the DTC memory..
2. If necessary, erase DTC memory of the Transmission Control Module (TCM) J217..
3. Generate readiness code..

Solenoid valve 1, checking

Note. The Solenoid Valve 1 N88 is a component of the Mechatronic unit in the transmission.

Requirements

1. The battery voltage must be at least 12.5 Volts.
2. All electrical consumers must be switched off.
3. The parking brake must be engaged.
4. The elector lever must be in the "P" position.

1. The Ground (GND) connections to transmission must be OK.

Test sequence

1. Disconnect the electrical connector in the - direction of the arrow - and remove it from the Transmission Control Module (TCM) J217.
2. Observe safety precautions.
3. Check the electrical harness connector for contact corrosion and ingress of water.

If the electrical harness connector is not OK

1. Repair the malfunction.

If the electrical harness connector is OK

1. Check the wiring according to the wiring diagram

If no malfunctions are found in the wiring

1. Replace the Mechatronic unit in the transmission: --> «38 GEARS, CONTROL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) .

Note. The Solenoid Valve 1 N88 is a component of the Mechatronic unit and cannot be replaced separately.

Final procedures

1. Check the DTC memory..
2. If necessary, erase DTC memory of the Transmission Control Module (TCM) J217..
3. Generate readiness code.

Pressure regulator valves, checking

Note. The Automatic Transmission Pressure Regulating Valve 1 N215 , Automatic Transmission Pressure Regulating Valve 2 N216 , Automatic Transmission Pressure Regulating Valve 3 N217 , Automatic Transmission Pressure Regulating Valve 4 N218 , Automatic Transmission Pressure Regulating Valve 5 N233 , and the Automatic Transmission Pressure Regulating Valve 6 N371 are components of the Mechatronic unit in the transmission.

Requirements

1. The battery voltage must be at least 12.5 Volts.
2. All electrical consumers must be switched off.
3. The parking brake must be engaged.
4. The elector lever must be in the "P" position.

1. The Ground (GND) connections to transmission must be OK.

Test sequence

1. Disconnect the electrical connector in the - direction of the arrow - and remove it from the Transmission Control Module (TCM) J217.
2. Observe safety precautions.
3. Check the electrical harness connector for contact corrosion and ingress of water.

If the electrical harness connector is not OK

1. Repair the malfunction.

If the electrical harness connector is OK

1. Check the wiring according to the wiring diagram

If no malfunctions are found in the wiring

1. Replace the Mechatronic unit in the transmission: --> «38 GEARS, CONTROL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) .

Note. The Automatic Transmission Pressure Regulating Valve 1 N215 , Automatic Transmission Pressure Regulating Valve 2 N216 , Automatic Transmission Pressure Regulating Valve 3 N217 , Automatic Transmission Pressure Regulating Valve 4 N218 , Automatic Transmission Pressure Regulating Valve 5 N233 , and the Automatic Transmission Pressure Regulating Valve 6 N371 are components of the Mechatronic unit in the transmission and cannot be replaced separately.

Final procedures

1. Check the DTC memory..
2. If necessary, erase DTC memory of the Transmission Control Module (TCM) J217..
3. Generate readiness code..

Function

The Transmission Control Module (TCM) J217 receives information from the components that affect the shifts and forwards this information to the pressure regulator valves of the mechatronic, which control the slide valves in the valve body.

Transmission Control Module (TCM) J217 , replacing

Note. The Transmission Control Module (TCM) J217 is a component of the mechatronic unit in the transmission and cannot be replaced separately. To achieve optimal anti-theft protection for the vehicle, an anti-theft immobilizer was installed. The anti-theft immobilizer is a system for enabling/locking the Transmission Control Module (TCM) J217. So that this system cannot be circumvented, it is necessary to perform adaptation of the anti-theft immobilizer using the Vehicle Diagnosis Service Syst. VAS5052 in the On Board Diagnostic (OBD) function. If the Transmission Control Module (TCM) J217 must be replaced, the vehicle may be taken to the nearest Audi dealership.

Work procedure

First, check the control module identification of the previous Transmission Control Module (TCM) J217 as follows

1. Connect the Vehicle Diagnosis Service Syst. VAS5052.
2. Switch the ignition on.
3. In diagnostic function "address word 33 - OBD" select "Diagnostic mode 9: Vehicle information."
4. Select the "Test-ID 04: Calibration identification".

1. The Transmission Control Module (TCM) J217 identification will be displayed, e.g.: 09G27750 L 0301
2. End diagnosis and switch the ignition off.
3. Replace the Mechatronic unit in the transmission: --> «38 GEARS, CONTROL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) .
4. Check the identification of the new Transmission Control Module (TCM) J217 to ensure it matches the old Transmission Control Module (TCM) J217.

1. Code the Transmission Control Module (TCM) J217 --> «Diagnostic Mode 09: Vehicle information»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__diagnostic-mode-09-vehicle-information) .
2. Generate readiness code. --> «Readiness Code Description»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__readiness-code-description) .

Voltage supply for the Transmission Control Module (TCM) J217 , checking

Note. The Transmission Control Module (TCM) J217 is a component of the mechatronic unit in the transmission and cannot be replaced separately.

Special tools, testers and auxiliary items required

1. Multimeter V.A.G 1526 A or equivalent.
2. Wiring diagrams.

Requirements

1. The fuses for the transmission electronics OK..
2. The battery voltage must be at least 12.5 volts.
3. The Ground (GND) connections at the transmission OK.
4. The parking brake engaged.

1. The selector lever of automatic transmission in position "P".
2. All electrical consumers switched off.
3. The ignition switched off.

Test sequence

1. Release the electrical connector in the - direction of the arrow - and remove it from the Transmission Control Module (TCM) J217.

Observe safety precautions.

1. Check the electrical harness connector for contact corrosion and ingress of water.

If the electrical harness connector is not OK

1. Repair the malfunction.

If the electrical harness connector is OK

1. Check the wiring according to the wiring diagram

If no malfunctions are found in the wiring

1. Replace the Mechatronic unit in the transmission: --> «38 GEARS, CONTROL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) .

Note. The Transmission Control Module (TCM) J217 is a component of the Mechatronic unit and cannot be replaced separately.

Final procedures

1. Check the DTC memory..
2. If necessary, erase DTC memory of the Transmission Control Module (TCM) J217..
3. Generate readiness code..

Continuously Variable Transmission (CVT) 01J, checking

For electrical diagnosis of the Continuously Variable Transmission (CVT) 01J, refer to the -->

1. «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
2. «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Generic Scan Tool (GST) Manual Contents

Included in the contents of this Generic Scan Tool (GST) manual is a summary table of the vehicle specific OBD II Emission Related Engine and Transmission DTCs. This table contains all necessary Malfunction Criteria, Threshold Values, Secondary Parameters, Enabling Conditions, Monitoring Time Length, Frequency of Checks, and Mil. Illumination to accurately monitor and diagnose the Engine Emissions and Transmission and perform all functions required to run Modes 01 through 09 with a hand held scan tool.

This Generic Scan Tool (GST) manual also contains the step by step pin point test procedures to accurately diagnose and repair the suspected component or system once a DTC has been set. All references to repair procedures and wiring diagrams will be found within the diagnostic test procedure and easily identified as. e.g. --> 24 - MULTIPORT FUEL INJECTION (MFI) or 2005 A4 2.0L TSFI Engine Wiring Diagrams.

On Board Diagnostic (OBD) Systems

OBD II

OBD is an abbreviation for the On Board Diagnostic System.

California OBD-II applies to all gasoline engine vehicles up to 14,000 lbs. Gross Vehicle Weight Rating (GVWR) starting in the 1996 MY and all diesel engine vehicles up to 14,000 lbs. GVWR starting in the 1997 MY.

Several states in the Northeastern United States have chosen to adopt the California emission regulations starting in the 1998 MY and are known as "Green States".

Green States receive California-certified vehicles for passenger cars and light trucks up to 6,000 lbs. GVWR. Starting in the 2004 MY, Federal vehicle over 8,500 lbs. will start phasing in OBD-II.

Starting in 2004 MY, gasoline-fueled Medium Duty Passenger Vehicles (MDPVs) are required to have OBD-II. Federal OBD-II applies to all gasoline engine vehicles up to 8,500 lbs. GVWR starting in the 1996 MY and all diesel engine vehicles up to 8,500 lbs. GVWR starting in the 1997 MY.

OBD-II system implementation and operation is described in the remainder of this document.

Serial Data Link (MIL) Illumination

MIL is an abbreviation for the Malfunction Indicator Lamp (MIL).

If the Engine Control Module (ECM) recognizes a malfunction that leads to increased emissions values, it indicates them by lighting the Malfunction Indicator Lamp (MIL) which is located in the instrument cluster.

The Engine Control Module (ECM) switches on the Malfunction Indicator Lamp (MIL) after the ignition is switched on. Shortly after the engine is started, The Malfunction Indicator Lamp (MIL) goes out if the Engine Control Module (ECM) does not detect a malfunction that increases the emissions values.

If the Engine Control Module (ECM) recognizes a malfunction that leads to increased emissions during the operation of the engine, the Engine Control Module (ECM) switches on the Malfunction Indicator Lamp (MIL) and an entry is stored in the DTC memory of the Engine Control Module (ECM).

Controller Area Network (CAN) Data Link

CAN is an abbreviation for Controller Area Network.

The Engine Control Module (ECM) communicates with all databus capable control modules via a CAN Data Link.

The databus capable control modules (i.e. Engine Coolant temperature Sensor) are connected via two data bus wires which are twisted together (CAN_High and CAN_Low), and exchange information (messages) to the Engine Control Module (ECM). Missing information on the databus is then recognized and stored as a malfunction.

The Engine Control Module (ECM) illuminates the Malfunction Indicator Lamp (MIL) through the CAN data link and tells the Malfunction Indicator Lamp (MIL) to turn on, turn off, or blink.

Electronic Power Control (EPC) Warning Lamp

EPC is an abbreviation that stands for the Electronic Power Control (E-gas).

The Engine Control Module (ECM) monitors all EPC components after the ignition is switched on.

If a malfunction is recognized in the EPC system during the operation of the engine, the Engine Control Module (ECM) switches on the Electronic Power Control (EPC) Warning Lamp which is located in the instrument cluster and an entry is stored in the DTC memory of the Engine Control Module (ECM).

Diagnostic Modes Description

The information provided in Modes 01 through 09 displays the various levels of emission related data that may be monitored, as well as the ability to retrieve and read stored DTC trouble codes , erase stored DTC trouble codes, generate readiness codes, and select the various PIDs and Test-IDs used within the modes to monitor the engine, and emission related component parameters.

The following table provides a link to all diagnostic modes that monitor all components and systems which influence the emission quality.

Note. Depending on diagnostic tester and protocol used, the information in diagnostic mode 01 may be referred to by different names such as Test-ID (TID), Hex-ID, Component-ID (CID), or On-Board Diagnostic Monitor Identifier (OBDMID).

Diagnostic Mode 01: Obtain data

Diagnostic Mode 01 is used to display and monitor all emissions related measured values.

Test requirement

1. Coolant temperature at least 80°C.

Procedure

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Diagnostic Mode 1: Obtain data.".
4. From the following table, select the desired the "PID" that is to be monitored, e.g. "PID 05-Coolant temperature".

Note. More than one "PID" may be selected and monitored.

The current values of the component or system that is being monitored will be displayed on the diagnostic tester screen.

1. Switch the ignition off.
2. End of diagnosis.

Diagnostic Mode 02: Obtain operating conditions

Diagnostic Mode 02 is used to monitor the operating conditions under which the Engine Control Module (ECM) has detected and stored an emissions related DTC.

Note. Depending on diagnostic tester and protocol used, the information in diagnostic mode 02 may be referred to by different names such as Test-ID (TID), Hex-ID, Component-ID (CID), or On-Board Diagnostic Monitor Identifier (OBDMID).

Procedure

1. Connect the diagnostic tester.
2. Start the engine and run at idle.

Note. If the engine does not start, crank the engine using starter for at least 5 seconds, do not switch the ignition off afterward under any circumstances.

1. Select "Diagnostic Mode 2: Obtain operating conditions.".
2. From the following table, select the desired the "PID" , e.g. "PID 05-Coolant temperature" that is to be monitored.

Note. More than one "PID" may be selected and monitored.

The current values of the component or system that is being monitored will be displayed on the diagnostic tester screen.

1. Switch the ignition off.
2. End of diagnosis.

Mode 03: Interrogating fault memory

Description

When the Engine Control Module (ECM) recognizes an emission related fault it turns on the Malfunction Indicator Lamp (MIL) or if a Electronic Throttle Malfunction is recognized, the Engine Control Module (ECM) turns on the Electronic Power Control (EPC) Warning Lamp which are both located in the instrument cluster.

Diagnostic Mode 03 is used to retrieve and view any DTC which may be stored in the Engine Control Module (ECM).

The DTCs are sorted by SAE code with the DTC tables consisting of a 5-digit alpha-numeric value.

Note. Depending on diagnostic tester and protocol used, diagnostic mode 03 and the information provided may be referred to by a different name.

The following tables provide a breakdown and explanation of the DTC code.

P-Codes

U-Codes

Interrogating the Fault Memory

Procedure

1. Connect the diagnostic tester.
2. Switch the ignition to the "ON" position.
3. Select "Diagnostic Mode 03: Interrogating fault memory ".
4. The stored DTC or DTCs will be displayed on the diagnostic tester screen.

The following table is an example of the DTC information that may be displayed on the diagnostic tester screen

1. Refer to the following DTC tables for the diagnostic repair procedure

1. SAE P0xxxDTCs. --> «SAE P0xxx-DTCs»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg) .
2. SAE P1xxx-DTCs --> «SAE P1xxx-DTCs»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg) .
3. SAE P2xxxDTCs. --> «SAE P2xxx-DTCs»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg) .
4. SAE P3xxxDTCs. --> «SAE P3xxx-DTCs»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg) .

1. SAE U0xxxDTCs, --> «SAE U0xxx-DTCs»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg) .

Fuel, air mixture, and additional emissions regulations

1. Switch the ignition off.
2. End of diagnosis.

Diagnostic Mode 04: Reset/delete diagnostic data

Diagnostic Mode 04 is used to reset or delete the following stored information

1. All emission related malfunctions in the DTC memory.
2. The operating conditions at which a malfunction was stored will be reset.
3. All adaptation values.
4. The test results of all diagnostic functions.

Note. Depending on diagnostic tester and protocol used, diagnostic mode 04 and the information provided may be referred to by a different name.

Procedure

1. Connect the diagnostic tester.
2. Switch the ignition to the "ON" position.
3. Select "Diagnostic Mode 03: Interrogating fault memory ".
4. Then select "Mode 4: Reset/delete diagnostic data".

The diagnostic tester will display: "Diagnostic data are being erased".

1. Switch the ignition off.
2. End of diagnosis.

Diagnostic Mode 05: Check lambda test results

Note. The diagnostic information for "Diagnostic Mode 5: check lambda test results" is not supported in this section of the 2005 Audi A4 2.0L TFSI Generic Scan Tool (GST) service manual and has been moved to "Diagnostic Mode 6: Checking test results of components that are not continuously monitored" section. Refer to "Diagnostic Mode 6: Checking test results of components that are not continuously monitored" for the static values of all oxygen sensors and all emission related components --> Diagnostic Mode 06: Checking test results of components that are not continuously monitored .

Note. Depending on diagnostic tester and protocol used, diagnostic mode 05 and the information provided may be referred to by a different name.

Diagnostic Mode 06: Checking test results of components that are not continuously monitored

Diagnostic Mode 06 displays the test results of emission related components and systems which are not continuously monitored.

The values of the individual test results must reach the specified value or must be within the min. and max. limits.

Note. Depending on diagnostic tester and protocol used, the information in diagnostic mode 06 may be referred to by different names such as Test-ID (TID), Hex-ID, Component-ID (CID), or On-Board Diagnostic Monitor Identifier (OBDMID).

Test requirements

1. Exhaust system must be properly sealed between the catalytic converter and the cylinder heads.
2. No DTCs stored in the DTC memory.
3. Coolant temperature at least 80°C.

Work procedure

1. Connect the diagnostic tester.
2. Start the engine and run at idle.

Note. If the engine does not start, crank the engine using starter for at least 5 seconds, do not switch the ignition off afterward under any circumstances.

1. Select "Mode 6: Check test the results of components that are not continuously monitored".
2. Select the desired "Test-ID" of the component or system that is to be monitored, e.g. "Test-ID 01: Oxygen Sensor Monitor Bank 1 - Sensor 1".
3. Select the desired "Test-ID".

The current minimum and maximum values will be displayed on the diagnostic tester screen.

The following table is a numerical list of all "Test-IDs" or "Hex-IDs" that may be selected.

Test-ID 01 ($01): Oxygen Sensor Monitor Bank 1 - Sensor 1

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Test-ID 01 ($01) ".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 02 ($02): Oxygen Sensor Monitor Bank 1- Sensor 2

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Test-ID 02 ($02)".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of the components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 33 ($21): Catalytic Converter Monitoring

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Test-ID 33 ($21)".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of the components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 59 ($3B): Fuel Tank EVAP System Integrity/LeakTest (0.40/1.0mm)

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Test-ID 59 ($3B)".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of the components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 60 ($3C): Fuel Tank EVAP System Integrity/LeakTest (0.20/0.5mm)

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Test-ID 60 ($3C)".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of the components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 61 ($3D): EVAP Valve Function Check

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Test-ID 61 ($3D)".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of the components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 65 ($41): Oxygen Sensor Heater Monitor Bank 1 - Sensor 1

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Test-ID 65 ($41)".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of the components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 66 ($42): Oxygen Sensor Heater Monitor Bank 1 - Sensor 2

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Test-ID 66 ($42)".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of the components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 162 ($A2): Mis-Fire Cylinder 1 Data

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Test-ID 162 ($A2)".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of the components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 163 ($A3): Mis-Fire Cylinder 2 Data

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6 Check test the results of components that are not continuously monitored".

Select "Test-ID 163 ($A3):".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of the components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 164 ($A4): Mis-Fire Cylinder 3 Data

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Test-ID 164 ($A4)".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of the components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 165 ($A5): Mis-Fire Cylinder 4 Data

1. Connect the diagnostic tester.
2. Start the engine and run at idle.
3. Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Test-ID 165 ($A5)".

1. Select the desired "Test-ID (TID)" or "Hex-ID".
2. Check specified values at idle.

1. If any of the components or systems fail to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure --> «Mode 03: Interrogating fault memory»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg__mode-03-interrogating-fault-memory) .
2. Switch the ignition off.
3. End of diagnosis.

Diagnostic Mode 07: Check test results of components that are continuously monitored

Diagnostic Mode 07 displays all stored DTCs of emission related components and systems which are continuously monitored.

Note. Depending on diagnostic tester and protocol used, diagnostic mode 07 and the information provided may be referred to by a different name.

Test requirements

1. No DTCs stored in the DTC memory.
2. Coolant temperature at least 80°C.

Procedure

1. Connect the diagnostic tester.
2. Start the engine and run at idle.

Note. If the engine does not start, crank the engine using starter for at least 5 seconds, do not switch the ignition off afterward under any circumstances.

1. Select "Mode 7: Check test results of components that are continuously monitored".

The number of stored DTCs or "0 malfunctions detected" will be displayed diagnostic tester screen.

1. Switch the ignition off.
2. Refer to the following DTC tables for the diagnostic repair procedure

1. SAE P0xxxDTCs. --> «SAE P0xxx-DTCs»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg) .
2. SAE P1xxx-DTCs --> «SAE P1xxx-DTCs»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg) .
3. SAE P2xxxDTCs. --> «SAE P2xxx-DTCs»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg) .
4. SAE P3xxxDTCs. --> «SAE P3xxx-DTCs»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg) .

1. SAE U0xxxDTCs, --> «SAE U0xxx-DTCs»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-generic-scan-tool-motronic-fuel-injection-system-ignition-system-engine-code-bpg) .

1. Switch the ignition off.
2. End of diagnosis.

Diagnostic Mode 08: Tank leak test

Diagnostic Mode 08 is used to test the fuel system for leaks.

Note. Depending on diagnostic tester and protocol used, diagnostic mode 08 and the information provided may be referred to by a different name.

Note. If the accelerator pedal is depressed during the test, the test will be aborted.

Test requirements

1. No DTCs stored in the DTC memory.
2. Intake Air Temperature (IAT) maximum 60°C.
3. Coolant temperature 80 to 110°C.
4. Throttle valve angle 12.0 to 16.0%.

Procedure

1. Connect the diagnostic tester.
2. Start the engine and run at idle for at least 15 minutes.
3. Select "Mode 8: Tank Leak Test".
4. Select "Test-ID 01: Tank Leak Test".

1. Check the specified value of the tank leak test at idle.
2. The following will be displayed on the diagnostic tester screen

1. Switch the ignition off.

If the specified value is obtained

1. Refer to "Diagnostic mode 03: Interrogating fault memory " to check for any DTCs that may be stored.
2. To repeat the tank test, switch the ignition off and start the engine again and let run for 15 minutes at idle.
3. Switch the ignition off.
4. End of diagnosis.

Diagnostic Mode 09: Vehicle information

Note. For all calibration and immobilizer information.

Diagnostic Mode 09 is used to display vehicle specific information, e.g. the different Engine Control Module (ECM) versions.

Note. Depending on diagnostic tester and protocol used, diagnostic mode 09 and the information provided may be referred to by a different name.

Test requirement

1. No DTCs stored in the DTC memory.

Procedure

1. Connect the diagnostic tester.
2. Switch the ignition on.
3. Select "Mode 09: Vehicle information".
4. Select the desired "Test-ID".

1. The information requested will be displayed on the diagnostic tester screen.

The following table is a numerical list of all "Test-IDs" that may be selected.

1. Switch the ignition off.
2. End of diagnosis.

Readiness Code Description

Diagnostics are performed at regular intervals during normal vehicle operation. After repairing an emissions related system, a readiness code is generated by road testing the vehicle.

If a malfunction is recognized during the drive cycle, it will be stored in the DTC memory.

The OBD drive cycle operation will be monitored with a hand held diagnostic tool. Consult the manufacturers instruction manual for correct tool operation.

The readiness code is erased every time the DTC memory is erased or any time the battery is disconnected. If the DTC memory has been erased or the battery is disconnected, a new readiness code must be generated.

Only erase the DTC memory if a DTC has been stored.

General Recommendations

Most monitors will complete easier and quicker using a steady-foot and smooth acceleration during the drive cycle operation, cruise, and acceleration modes.

Operating Conditions

For the EVAP monitor test, the coolant temperature and the ambient air temperature must be between 10°C and 35°C with a difference between them no greater than 4°C. The ambient air temperature must not change more than 4°C during the drive cycle procedure (e.g. when driving out of a heated workshop in the winter).

Test requirements

1. Erase the DTC memory.
2. Coolant temperature must be between 80°C and 110°C.
3. The Intake Air Temperature (IAT) must be between 10°C and 35°C.
4. Battery voltage must be a minimum of 12.5 volts.

1. Fuel tank level 1/4 to 3/4 full.

Drive Cycle Procedure

1. Connect the diagnostic tester.
2. Switch the ignition on and start the vehicle.
3. Idle the vehicle for 2-3 minutes. This executes the O2S Heater, Misfire, Secondary AIR, Fuel Trim, and Purge system monitors.
4. Drive the vehicle at 45-55 mph for a continuous 7-minute period, avoid stopping. This executes the EVAP, O2S, Fuel Trim, and Misfire monitors.

1. Accelerate the vehicle to an engine speed of 5000 RPM (with automatic transmission use the tip-tronic mode); lift off the throttle until the engine speed is around 1200 rpm. This executes the fuel cut off
2. Accelerate the vehicle smoothly to 60-65 mph, cruise constantly for 5 min, this executes the Catalyst; O2S, Misfire, Fuel Trim, and Purge System monitors.
3. Decelerate and idle the vehicle again for 3 minutes. This executes the Misfire, Secondary AIR, Fuel Trim, and Purge system monitors.
4. Check the status of the readiness code.

Note. Depending on the diagnostic tester used. The readiness code status may be displayed as complete, passed or OK.

1. If any engine monitor fails the drive cycle test. Repeat the drive cycle test until all engine monitors have successfully run through and passed.

Note. When repeating the drive cycle operation for a failed EVAP monitor or thermostat-monitor, allow the engine to cool until the coolant temperature and the ambient air temperature are be between 10°C and 35°C with a difference between them no greater than 4°C is observed and repeat the drive cycle operation.

If the drive cycle operation fails again.

1. Check the DTC memory for stored DTCs.

Repair the vehicle if necessary.

1. Repeat the drive cycle operation until all engine monitors have successfully run through and passed.
2. Remove the diagnostic tester and switch the ignition off.
3. End of operation.

Fuel, air mixture, and additional emissions regulations

Fuel and air ratios

Additional exhaust regulation

Speed and idle control

Control module and output signals