Ignition/glow Plug System, Generic Scan Tool (2.7l v6 Biturbo - Apb, Bel) Audi A6 C5 рестайлинг

Ignition system, general notes

1. This section deals specifically with ignition -related components. The other components of the injection and ignition system, see «COMPONENT OVERVIEW»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#multiport-fuel-injection-mfi-generic-scan-tool-27l-v6-biturbo-apb-bel__component-overview) .
2. For the electric components to work properly, a voltage of at least 11.5 V is required.
3. The battery must only be disconnected and connected with the ignition switched off, since the Engine Control Module (ECM) can otherwise be damaged.
4. The Engine Control Module (ECM) is equipped with an On Board Diagnostic (OBD)
5. Components marked with * are tested via On Board Diagnostic (OBD). See «DIAGNOSTIC MODE 3: CHECK DTC MEMORY»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel) .
6. 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. - Check DTC memory. See «DIAGNOSTIC MODE 3: CHECK DTC MEMORY»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel) . - Erase DTC memory. See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel) - For completion, generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel) .

Safety precautions, see SAFETY PRECAUTIONS .

Test data, spark plugs, see TEST DATA, SPARK PLUGS .

Camshaft adjustment, servicing

Removing and installing camshaft and camshaft adjuster

See CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING .

Safety precautions

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following

1. Do not touch or disconnect ignition wires when engine is running or turning at starting RPM.
2. Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition is turned off.
3. If it is desired to turn engine at starting RPM without starting it, for example during the compression test, disconnect connector of power output stages for ignition coils and connector for fuel injectors as well as remove Fuel Pump (FP) fuse (28).

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.

Test Data, Spark Plugs

TEST DATA, SPARK PLUGS

Recommended special tools and equipment

1. VAG1526 multimeter or VAG1715 multimeter
2. VAG1594 connector test kit
3. Wiring diagram

Test requirements

1. The respective fuses of Motronic Engine Control Module (ECM) - J220- must be OK: See appropriate System Wiring Diagrams article.
2. Battery voltage must be at least 11.5 volts.
3. All electrical consumers like, for example, lights and rear window heating must be switched off.
4. Parking brake must be engaged or else daylight driving lights will be switched on.
5. Ground (GND) connections between engine and chassis must be OK.

Test sequence

1. Disconnect 3-pin connectors from Camshaft Position (CMP) sensors. The locations of the Camshaft Position (CMP) sensors are as follows

1. Cylinder bank 1 Camshaft Position (CMP) Sensor -G40-Right front cylinder head
2. Cylinder bank 2 Camshaft Position (CMP) Sensor 2 -G163-Left rear cylinder head

Note. Cylinder bank 1 = in driving direction, right Cylinder bank 2 = in driving direction, left Before disconnecting harness connectors, mark allocation to component.

Scheme 36

1. Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of the respective connector for Camshaft Position (CMP) sensor for voltage measurement.
2. Switch ignition on. Specified value: at least 5.0 V
3. Switch ignition off.

If there is no voltage

1. Connect test box to control module wiring harness. See «TEST BOX FOR WIRING TEST, CONNECTING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel__test-box-for-wiring-test-connecting) .
2. Check wires between test box and 3-pin connector for open circuits according to wiring diagram. Wire resistance: max: 1.5 ohm

CMP SENSOR CIRCUIT TEST: OPENS

1. Also check wires for short circuit to each other. Specified value: INFINITY ohm

If no malfunctions are found in the wires and there was voltage between terminals 1 & 3

1. Replace the respective Camshaft Position (CMP) sensor: Camshaft Position (CMP) Sensor -G40- cylinder bank 1, see «COMPONENT OVERVIEW»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#multiport-fuel-injection-mfi-generic-scan-tool-27l-v6-biturbo-apb-bel__component-overview) Camshaft Position (CMP) Sensor 2 -G163- cylinder bank 2, see «COMPONENT OVERVIEW»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#multiport-fuel-injection-mfi-generic-scan-tool-27l-v6-biturbo-apb-bel__component-overview)
2. Erase DTC memory of Engine Control Module (ECM), see «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel) .

If no errors are found in wires and there was no voltage between terminals 1 & 3

1. Replace Engine Control Module (ECM). See «ENGINE CONTROL MODULE (ECM), REPLACING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#multiport-fuel-injection-mfi-generic-scan-tool-27l-v6-biturbo-apb-bel__engine-control-module-ecm-replacing) .

Ignition coils, checking

Note. The following procedure is valid for vehicles with engine code "APB". The procedure for vehicles with engine code "BEL" is found in CHECKING IGNITION COILS, ENGINE CODE "BEL" .

Test requirement

1. No malfunction regarding fuel injector(s) stored

1. Disconnect connectors from fuel injectors in sequence with engine running and observe engine operation. or
2. Compare spark plugs of all cylinders to each other. Check electrodes for carbon fouling.

If faulty cylinder is recognized

1. Connect multimeter to spark plug connector for resistance measurement.

Note. Spark plug connector can be disconnected from ignition coil.

Specified value: approx. 2 k ohm

If specified value is not obtained

1. Replace spark plug connector.

If specified value is obtained

1. Switch spark plug from faulty cylinder with one from another cylinder. Beforehand, perform a visual check of spark plug for possible damage e.g. cracks in ceramic shell of spark plug.
2. If a malfunction now occurs at other cylinder, replace the spark plug.

If malfunction remains at original cylinder

1. Switch spark plug from faulty cylinder with one from another cylinder. Beforehand, perform a visual check of ignition coil for damage (ignition could be cracked or shattered).
2. If a malfunction now occurs at other cylinder, replace the ignition coil.

If malfunction remains at original cylinder

1. Disconnect connector on ignition coil.
2. Check Ground (GND) connection from terminal 4a to engine Ground (GND) for open circuit and short circuit to B+. See appropriate System Wiring Diagrams article.
3. Repair open circuit or short circuit if necessary.

If Ground (GND) connection is OK

1. Connect multimeter to terminal 15 of connector and Ground (GND) for voltage measurement.
2. Remove fuel injector from cylinder to be tested.
3. Operate starter. Specified value on multimeter: approx. battery voltage

If specified value is not obtained

1. Check wire connections. See appropriate System Wiring Diagrams article.

If specified value is obtained

1. Disconnect 3-pin connector from power output stages for ignition coils.
2. Then connect voltage tester to 3-pin connector of both output stages.
3. Connect voltage tester V.A.G 1527 to the following terminals of connector at power output stages. Then, operate starter for a few seconds.

POWER OUTPUT STAGE VOLTAGE SPECIFICATIONS (ENGINE CODE APB)

If specified values are not obtained

1. Switch ignition off.

The following wire connections must be checked for short circuit to B+, Ground (GND) and for open circuit

POWER OUTPUT STAGE CIRCUIT TEST: OPENS/SHORTS, BLACK CONNECTOR (ENGINE CODE APB)

POWER OUTPUT STAGE CIRCUIT TEST: OPENS/SHORTS, BROWN CONNECTOR (ENGINE CODE APB)

1. Repair open circuit or short circuit if necessary.

Checking ignition coils, engine code "BEL"

Note. The ignition coil and power output stage are combined in one complete component.

1. No malfunction regarding fuel injector(s) stored

Recognize a non-functional or misfiring cylinder as follows

1. Disconnect connectors from fuel injectors in sequence with engine running and observe engine operation. Or
2. Compare spark plugs of all cylinders to each other. Check electrodes for carbon fouling.

If faulty cylinder is recognized

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

If malfunction follows the spark plug

1. Replace spark plug.

If malfunction remains at original cylinder

1. Switch spark plug from faulty cylinder with one from another cylinder.
2. If a malfunction now occurs at other cylinder, replace the ignition coil.

If malfunction remains at the cylinder, check Ground (GND) wire of ignition coil.

Checking Ground (GND) wire of ignition coil

1. Disconnect the 4-pin connector at the respective ignition coil.
2. Check Ground (GND) connection from 4 -pin connector socket 4 to engine Ground (GND) for open circuit and short circuit to B+.
3. Repair open circuit or short circuit if necessary.

If Ground (GND) connection is OK: Check voltage supply of ignition coil. See CHECKING VOLTAGE SUPPLY OF IGNITION COIL .

Checking voltage supply of ignition coil

1. Connect multimeter to the following connector sockets for voltage measurement
2. Switch ignition on.

Scheme 37

IGNITION COIL CIRCUIT TEST: VOLTAGE SUPPLY (ENGINE CODE BEL)

Specified value: approx. battery voltage

If specified value is not obtained

1. Check wire connection from socket 1 via fuse to Motronic Engine Control Module (ECM) Power Supply Relay -J271- for continuity, repair if necessary. See appropriate System Wiring Diagrams article.

If specified value is obtained.

1. Check power output stage. See «CHECKING POWER OUTPUT STAGES FOR IGNITION COILS, ENGINE CODE "BEL"»(/audi/a6/c5-2001-2004/remont/ignition-system/#ignitionglow-plug-system-generic-scan-tool-27l-v6-biturbo-apb-bel__checking-power-output-stages-for-ignition) .

Power output stages for ignition coils, checking

Note. The following procedure is valid for engines with engine code "APB". The procedure for engines with engine code "BEL" is found in CHECKING POWER OUTPUT STAGES FOR IGNITION COILS, ENGINE CODE "BEL" . Power Output Stage -N122-; (black connector) activates ignition coils of cylinder bank 1 (cylinders 1 to 3). Power output stage 2 -N192-; (brown connector) activates ignition coils of cylinder bank 2 (cylinders 4 to 6).

Checking activation of power output stages

1. Pull connectors off all six fuel injectors.

Note. Fuel must not be injected during the test to avoid damaging catalytic converter. Connectors must therefore be disconnected from fuel injectors.

1. Disconnect 4-pin connector from power output stages. For overview of component locations. See «COMPONENT OVERVIEW»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#multiport-fuel-injection-mfi-generic-scan-tool-27l-v6-biturbo-apb-bel__component-overview) .
2. Connect voltage tester V.A.G 1527 in succession to the following terminals of both 4-pin connectors at power output stages; then operate starter for a few seconds.

Scheme 38

POWER OUTPUT STAGE VOLTAGE SPECIFICATIONS (ENGINE CODE APB)

If specified values are not obtained

1. Switch ignition off.
2. Connect test box to control module wiring harness. See «TEST BOX FOR WIRING TEST, CONNECTING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel__test-box-for-wiring-test-connecting) .

The following wire connections must be checked for short circuit to B+, Ground (GND) and for open circuit

POWER OUTPUT STAGE CIRCUIT TEST: OPENS/SHORTS, BLACK CONNECTOR (ENGINE CODE APB)

POWER OUTPUT STAGE CIRCUIT TEST: OPENS/SHORTS, BROWN CONNECTOR (ENGINE CODE APB)

1. Repair open circuit or short circuit if necessary.

If no wiring faults are found

1. Connect 4-pin connectors to power output stages.
2. Disconnect 3 -pin connector from power output stages.
3. Connect voltage tester V.A.G 1527 to battery plus (B+) and to one of the terminals at 3 -pin output of the respective power output stage.
4. Operate starter for a few seconds. LED must blink.
5. Perform the test at all 3 terminals at 3 -pin connectors of the respective power output stage. LED must blink respectively.

If LED does not blink at one or more outputs

Check Ground (GND) supply for output stages as follows

1. Disconnect 4 -pin connector from output stages.
2. Connect voltage tester V.A.G 1527 to B+ and to terminal 2 of 4-pin connector. LED must light up.
3. If LED does not light up, check wire connection for open circuit according to wiring diagram. See appropriate System Wiring Diagrams article. If LED lights up
4. Replace power output stage.

Checking power output stages for ignition coils, engine code "BEL"

Note. The ignition coil and power output stage are combined in one complete component.

Checking Ground (GND) supply of power output stage

1. Disconnect the 4-pin connector at the respective ignition coil.
2. Check Ground (GND) connection from 4-pin connector socket 2 to chassis Ground (GND) for open circuit and short circuit to B+.
3. Repair open circuit or short circuit if necessary. See appropriate System Wiring Diagrams article.

If Ground (GND) connection is OK: Check activation of power output stages, see CHECKING ACTIVATION OF POWER OUTPUT STAGES .

1. Pull connector off all fuel injectors.

Note. Fuel must not be injected during the test to avoid damaging catalytic converter. Connectors must therefore be disconnected from fuel injectors.

Scheme 39

1. Disconnect the 4-pin connector at the respective ignition coil.
2. Connect voltage tester V.A.G 1527 to the following terminals of connector for ignition coil.
3. Operate starter for a few seconds.

POWER OUTPUT STAGE VOLTAGE SPECIFICATIONS (ENGINE CODE BEL)

If specified values are not obtained

1. Switch ignition off.
2. Connect test box to control module wiring harness. See «TEST BOX FOR WIRING TEST, CONNECTING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel__test-box-for-wiring-test-connecting) .
3. Check wire connection from 4 -pin connector at ignition coil or power output stage to Engine Control Module (ECM) for wiring open circuit as well as short circuit to B+ and to Ground (GND).

Scheme 40

POWER OUTPUT STAGE CIRCUIT TEST (ENGINE CODE BEL)

Wire resistance: max: 1.5 Ohm

1. Repair open circuit or short circuit if necessary. See appropriate System Wiring Diagrams article.

If no wiring faults are found

1. Replace the combined component, ignition coil with power output stage.

Knock sensors, checking

Note. To remove and install Knock Sensors, intake manifold must be removed. Contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease. For the Knock Sensors to function properly, it is important for tightening torque to be exactly 20 Nm. Use only gold -plated terminals when servicing terminals in harness connector of knock sensors.

1. VAG1526 multimeter or VAG1715 multimeter
2. VAG1594 connector test kit
3. Wiring diagram

1. Knock sensor securing bolt tightened to 20 Nm.
2. Ignition switched off.

Checking resistances and wires

1. Disconnect 3-pin harness connector to knock sensors

1. Knock Sensor (KS) 1 -G61-, cylinder bank 1
2. Knock Sensor (KS) 2 -G66-, cylinder bank 2

Note. To reach the harness connector of Knock Sensor (KS) 2 -G66-, remove coolant reservoir securing screws and tilt coolant reservoir to the side. The coolant hoses remain connected. Cylinder bank 1 = in driving direction, right Cylinder bank 2 = in driving direction, left

1. Measure resistance between terminals 1 & 2, 1 & 3, and 2 & 3 at connectors to knock sensors. Specified value: INFINITY ohm
2. Connect test box to control module wiring harness. See «TEST BOX FOR WIRING TEST, CONNECTING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel__test-box-for-wiring-test-connecting) .
3. Check wires between test box and 3 -pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 ohm

KNOCK SENSOR CIRCUIT TEST: OPEN CIRCUIT

Scheme 41

1. Also check wires for short circuit to each other. Specified value: INFINITY ohm

If no wiring faults are found

1. Replace the respective knock sensor: Knock Sensor (KS) 1 -G61- cylinder bank 1, see «COMPONENT OVERVIEW»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#multiport-fuel-injection-mfi-generic-scan-tool-27l-v6-biturbo-apb-bel__component-overview) Knock Sensor (KS) 2 -G66- cylinder bank 2, see «COMPONENT OVERVIEW»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#multiport-fuel-injection-mfi-generic-scan-tool-27l-v6-biturbo-apb-bel__component-overview)
2. Erase DTC memory of Engine Control Module (ECM). See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel) .

Function

The camshaft adjustment is load - and RPM dependent. The electrical valves for camshaft adjustment switch oil pressure onto camshaft adjusters (mechanical adjustment mechanisms), which then adjust the camshafts.

1. VAG1526 multimeter or VAG1715 multimeter
2. VAG1594 connector test kit
3. Wiring diagram

Scheme 42

1. The respective fuses of the Valve -1- for camshaft adjustment - N205- and Valve -2- for camshaft adjustment -N208- must be OK: See appropriate System Wiring Diagrams article.
2. Fuel Pump (FP) Relay -J17- must be OK, check: See appropriate System Wiring Diagrams article.
3. Battery voltage must be at least 11.5 volts.
4. All electrical consumers like, for example, lights and rear window heating must be switched off.
5. Parking brake must be engaged or else daylight driving lights will be switched on.
6. If vehicle is equipped with an A/C system, it must be switched off.
7. Ground (GND) connections between engine and chassis must be OK.
8. Ignition switched off.

1. Disconnect 2-pin harness connector -1- to the respective Valve -2- for camshaft adjustment

Scheme 43

Note. Before disconnecting harness connectors, mark allocation to component.

1. Measure resistance between terminals of the respective valve for camshaft adjustment. Specified value: 10...18 ohm

Scheme 44

If specified value is not obtained

1. Replace the respective Valve -1- for camshaft adjustment -N205-/Valve -2- for camshaft adjustment -N208-. See «CAMSHAFT ADJUSTMENT, SERVICING»(/audi/a6/c5-2001-2004/remont/ignition-system/#ignitionglow-plug-system-generic-scan-tool-27l-v6-biturbo-apb-bel__camshaft-adjustment-servicing) .
2. Erase DTC memory of Engine Control Module (ECM). See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel) .

If specified value is obtained

1. Connect test box to control module wiring harness. See «TEST BOX FOR WIRING TEST, CONNECTING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-27l-v6-biturbo-apb-bel__test-box-for-wiring-test-connecting) .

Valve -1- for camshaft adjustment -N205

1. Check wire between test box socket 22 & 2-pin connector terminal 2 for open circuit according to wiring diagram. Wire resistance: max: 1.5 ohm
2. Also check wires for short circuit to B+ and Ground (GND). Specified value: INFINITY ohm
3. Check wire between 2 -pin connector terminal 1 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 ohm

If voltage supply and wires are OK

1. Replace Motronic Engine Control Module (ECM) -J220-. See «ENGINE CONTROL MODULE (ECM), REPLACING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#multiport-fuel-injection-mfi-generic-scan-tool-27l-v6-biturbo-apb-bel__engine-control-module-ecm-replacing) .

Valve -2- for camshaft adjustment -N208

1. Check wire between test box socket 18 & 2-pin connector terminal 2 for open circuit according to wiring diagram. Wire resistance: max: 1.5 ohm
2. Also check wires for short circuit to B+ and Ground (GND). Specified value: INFINITY ohm
3. Check wire between 2 -pin connector terminal 1 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 ohm

If voltage supply and wires are OK

1. Replace Motronic Engine Control Module (ECM) -J220-. See «ENGINE CONTROL MODULE (ECM), REPLACING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#multiport-fuel-injection-mfi-generic-scan-tool-27l-v6-biturbo-apb-bel__engine-control-module-ecm-replacing) .

See also:
• COMPONENT OVERVIEW
• DIAGNOSTIC MODE 3: CHECK DTC MEMORY
• CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING
• ENGINE CONTROL MODULE (ECM), REPLACING
• TEST BOX FOR WIRING TEST, CONNECTING
• SAFETY PRECAUTIONS
• TEST DATA, SPARK PLUGS
• CHECKING IGNITION COILS, ENGINE CODE "BEL"
• CHECKING VOLTAGE SUPPLY OF IGNITION COIL
• CHECKING POWER OUTPUT STAGES FOR IGNITION COILS, ENGINE CODE "BEL"
• CHECKING ACTIVATION OF POWER OUTPUT STAGES
• CAMSHAFT ADJUSTMENT, SERVICING