Ignition/glow Plug System, Generic Scan Tool (3.0l v6 Avk) Audi A6 C5 рестайлинг

General notes on ignition system

1. For the electric components to work properly, a voltage of at least 12.7 V is required.
2. It is possible that the control module will recognize a malfunction and store a DTC during some tests. After completing all tests and repairs, DTC memory should therefore be checked and erased if necessary. Readiness code must be generated after DTC memory is erased. See «READINESS CODE, GENERATING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk) .
3. If the engine only starts briefly and then turns off again after troubleshooting, repair or checking of the components, it may be that the immobilizer is blocking the Engine Control Module (ECM). DTC memory must then be checked and if necessary, control module must be adapted.

1. Note radio code (for vehicles equipped with coded anti - theft radio / radio navigation system), determine if necessary.
2. Disconnect Ground (GND) wire at battery Ground (GND) terminal with the ignition switched off.

Note. Be sure to activate vehicle features (radio/radio - navigation system, clock, electric window regulators) according to owner's manual when the battery is re - connected. Deactivate service mode of Telematics Control Module. See EMERGENCY BATTERY, SWITCHING OFF/ON . Generate readiness code. See READINESS CODE, GENERATING .

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. Always switch ignition off before disconnecting or reconnecting wires for the injection and ignition system, including high voltage wiring and test leads.
3. If engine is to be cranked at starting RPM without starting (e.g. for compression testing), disconnect connector from ignition coils and from fuel injectors.
4. It is possible that the control module will recognize a malfunction and store a DTC during some tests. After completing all tests and repairs, DTC memory should therefore be checked and erased if necessary. Readiness code must be generated after DTC memory is erased. See «READINESS CODE, GENERATING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk) .
5. Always switch ignition off before cleaning engine.

Technical data, ignition

TECHNICAL DATA, IGNITION

Scheme 117

1. VAG1526A multimeter
2. V.A.G 1527 B Voltage Tester
3. VAG1594A connector test kit
4. VAG1598/31 test box

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

Test requirement

1. Fuses for engine electronics OK

Procedure

1. Start engine and let run at idle.

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 ignition coil from faulty cylinder with one from another cylinder.

If malfunction follows the ignition coil

1. Replace ignition coil.

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

1. Remove cover -1- in engine compartment (left side).
2. Remove coolant reservoir (arrow)
3. Disconnect electrical wire from Engine Coolant Level (ECL) Warning Switch -F66- at bottom of reservoir.
4. Lay aside coolant reservoir with connected coolant hoses -1- to -3-.
5. Remove cover -1- in engine compartment (right side).
6. Remove bolts (arrows). (Scheme 121)
7. Remove air guide -1-.
8. Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- (-1-) at air filter housing. (Scheme 122)
9. Remove air filter housing (arrows).
10. Remove bolts (arrows) on cylinder head at right. (Scheme 123)
11. Disconnect 4-pin harness connectors -1- to -3- at ignition coils.
12. Remove bolts (arrows) on cylinder head at left. (Scheme 124)
13. Disconnect 4-pin harness connectors -4- to -6- at ignition coils.
14. Connect V.A.G 1527 B voltage tester as follows: IGNITION COIL CIRCUIT TEST: GROUND CONNECTION Harness connector Terminal Measure to 2 B+ 4 B+ LED must light up.

If LED does not light up

1. Check the wire connections for open circuit. Specified value: Wire resistance max 1.5 ohm
2. If necessary, repair wire connection.

If LED lights up

Checking voltage supply

1. Connect multimeter for voltage measurement as follows: IGNITION COIL CIRCUIT TEST: VOLTAGE SUPPLY Harness connector Terminal Measure to 1 Engine Ground (GND)
2. Switch ignition on. Specified value: approx. battery voltage
3. Switch ignition off.

If specified value is obtained

1. Check activation of power output stages. See «CHECKING ACTIVATION OF POWER OUTPUT STAGES»(/audi/a6/c5-2001-2004/remont/ignition-system/#ignitionglow-plug-system-generic-scan-tool-30l-v6-avk__checking-activation-of-power-output-stages) .

If specified value is not obtained

Scheme 126

Scheme 127

Scheme 128

Scheme 129

1. Pull off rubber seal of plenum chamber cover in direction of arrow.
2. Remove cover -1- toward front.
3. Remove cover for E-box, plenum chamber (arrows).
4. Pry off Engine Control Module (ECM) retaining bracket (arrow) using a screwdriver and set control module aside.
5. Disconnect voltage supply relay -3-.
6. Perform the following tests marked with dots

Scheme 130

1. Check wire connection from 3-pin relay carrier in E -box, plenum chamber, position 2, terminal 8 to harness connector at ignition coil terminal 1.
2. Check Motronic Engine Control Module (ECM) voltage supply relay -J271-. See «CHECK MOTRONIC ENGINE CONTROL MODULE (ECM) POWER SUPPLY RELAY -J271 - AND ACTIVATION»(/audi/a6/c5-2001-2004/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-30l-v6-avk) .

Checking activation of power output stages

1. Harness connector at ignition coils disconnected

Scheme 131

1. Remove all harness connectors to injectors. NOTE: Fuel must not be injected during the test to avoid damaging catalytic converter. Connectors must therefore be disconnected from fuel injectors.
2. Connect V.A.G 1527 B voltage tester to connector terminals 2 and 3.
3. Operate starter briefly. LED must blink (brief blink signal).
4. Switch ignition off.

If LED does not blink

Scheme 132

1. Connect test box to wiring harness of Engine Control Module (ECM). See «TEST BOX, CONNECTING FOR WIRING AND COMPONENT TEST»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk) . ECM is NOT connected.
2. Check the following wire connections for open circuit according to wiring diagram: POWER OUTPUT STAGES CIRCUIT TEST: ACTIVATION Harness connector Terminal Test box Socket 3 (Cyl. 1) 102 3 (Cyl. 2) 110 3 (Cyl. 3) 94 3 (Cyl. 4) 103 3 (Cyl. 5) 111 3 (Cyl. 6) 95 Specified value: Wire resistance max 1.5
3. Also check wires for short circuit to each other as well as to B+ and Ground (GND). Specified value: (no continuity)
4. If necessary, repair wire connection.

If no malfunctions are found in wires

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

Final procedures

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

1. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk__mode-3-check-dtc-memory) .
2. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk__mode-4-reseterase-diagnostic-data) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk) .

1. End diagnosis and switch ignition off.

Scheme 133

1. VAG1526A multimeter
2. VAG1594A connector test kit
3. VAG1598/31 test box

1. Ignition switched off.

Note. Knock Sensor (KS) 1 -G61- and Knock Sensor (KS) 2 - G66- themselves cannot be electrically tested. When servicing terminals in harness connector of knock sensors, use only gold-plated terminals. For the knock sensors to function properly, it is important that tightening torque be exactly 20 Nm. Check harness connector from knock sensor to wiring harness for corrosion.

Checking knock sensor wiring

1. Disconnect electrical 3-pin harness connector -3- for Knock Sensor (KS) 1 -G61-.

Scheme 134

Scheme 135

1. Disconnect electrical 3 -pin harness connector -3- for Knock Sensor (KS) 2 -G66-.
2. Check all three terminals at knock sensor connector for short circuit to each other (terminal 1+2, 1+3, 2+3). Specified value: INFINITY ohm (no continuity) - the wires must not have any connection to each other.
3. If there is a connection, replace knock sensor.

If no malfunction can be found

Scheme 136

1. Connect test box to wiring harness of Engine Control Module (ECM). See «TEST BOX, CONNECTING FOR WIRING AND COMPONENT TEST»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk) . ECM is NOT connected.
2. Check the following wire connections for open circuit according to wiring diagram: Knock Sensor (KS) 1 -G61- (bank 1) KNOCK SENSOR CIRCUIT TEST: KNOCK SENSOR 1 -G61- (BANK 1) Harness connector Terminal Test box Socket 1 (signal) 106 2 (Ground -GND-) 99 3 (shielding) 108 Knock Sensor (KS) 2 -G66- (bank 2) KNOCK SENSOR CIRCUIT TEST: KNOCK SENSOR 2 -G66- (BANK 2) Harness connector Terminal Test box Socket 1 (signal) 107 2 (Ground -GND-) 99 3 (shielding) 108 Specified value: Wire resistance max 1.5 ohm
3. Also check wires for short circuit to each other as well as to B+ and Ground (GND). Specified value: INFINITY ohm (no continuity)
4. If necessary, repair wire connection.

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

1. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk__mode-3-check-dtc-memory) .
2. Erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk__mode-4-reseterase-diagnostic-data) .

1. 4 - Reset/erase diagnostic data.
2. 3 - Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk) . End diagnosis and switch ignition off.

Scheme 137

1. VAG1526A multimeter
2. V.A.G 1527 B Voltage Tester
3. VAG1594A connector test kit
4. VAG1598/31 test box

1. Ignition switched off.

Component location, see OVERVIEW OF COMPONENT LOCATIONS

Note. To reach the harness connectors at cylinder bank 2 (left), the left cover in engine compartment must be removed, the wire to Engine Coolant Level (ECL) Warning Switch at bottom on reservoir must be disconnected, bolt -arrow- of coolant reservoir must be unscrewed and set it aside. Coolant hoses -1- to -3- remain connected.

Scheme 138

Checking activation

1. Connect voltage tester V.A.G 1527 B with measuring probes and connector adapters from V.A.G 1594 A between socket 2 (CMP sensor signal) and socket 1 (B+); the harness connector remains connected.

Scheme 139

Note. Connector socket numbers are shown on the rear side of the connector.

1. Operate starter for a few seconds. 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 LED does not blink

Scheme 140

Scheme 141

1. Disconnect electrical harness connectors -1- and -2- at Camshaft Position (CMP) Sensor -G40- and Camshaft Position (CMP) Sensor 3 -G300-.
2. Disconnect electrical harness connectors -1- and -2- at Camshaft Position (CMP) Sensor -G163- and Camshaft Position (CMP) Sensor 3 -G301-.
3. Connect multimeter for voltage measurement as follows: CMP SENSOR CIRCUIT TEST: VOLTAGE SUPPLY Harness connector Terminal Measure to 1 Engine Ground (GND)
4. Switch ignition on. Specified value: about 5 V
5. Switch ignition off.

Checking signal wire

1. Connect multimeter for voltage measurement as follows: CMP SENSOR CIRCUIT TEST: SIGNAL WIRE Harness connector Terminal Measure to 2 Engine Ground (GND)
2. Switch ignition on. Specified value: approx. battery voltage
3. Switch ignition off.

Scheme 142

1. Connect multimeter for voltage measurement as follows: CMP SENSOR CIRCUIT TEST: GROUND (GND) WIRE Harness connector Terminal Measure to 3 B+ Specified value: about 10 V

If all specified values are being reached and the LED does not blink (measured between terminal 1 and 2 with starter and connector connected)

1. Replace Camshaft Position (CMP) sensor.

If specified values are not obtained

Scheme 143

1. Connect test box to wiring harness of Engine Control Module (ECM). See «TEST BOX, CONNECTING FOR WIRING AND COMPONENT TEST»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk) . ECM is NOT connected.
2. Check the following wire connections for open circuit according to wiring diagram: Camshaft Position (CMP) Sensor 2 -G40- (bank 1) CMP SENSOR CIRCUIT TEST: SENSOR 2 -G40- (BANK 1) Harness connector Terminal Test box Socket 1 (B+) 98 2 (signal) 87 3 (Ground -GND-) 108 Camshaft Position (CMP) Sensor 2 -G163- (bank 2) CMP SENSOR CIRCUIT TEST: SENSOR 2 -G163- (BANK 2) Harness connector Terminal Test box Socket 1 (B+) 98 2 (signal) 86 3 (Ground -GND-) 108 Camshaft Position (CMP) Sensor 2 -G300- (bank 1) CMP SENSOR CIRCUIT TEST: SENSOR 2 -G300- (BANK 1) Harness connector Terminal Test box Socket 1 (B+) 98 2 (signal) 81 3 (Ground -GND-) 108 Camshaft Position (CMP) Sensor 2 -G301- (bank 2) CMP SENSOR CIRCUIT TEST: SENSOR 2 -G301- (BANK 2) Harness connector Terminal Test box Socket 1 (B+) 98 2 (signal) 54 3 (Ground -GND-) 108 Specified value: Wire resistance max 1.5 ohm
3. Also check wires for short circuit to each other as well as to B+ and Ground (GND). Specified value: INFINITY ohm (no continuity)
4. If necessary, repair wire connection.

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

1. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk__mode-3-check-dtc-memory) .
2. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk__mode-4-reseterase-diagnostic-data) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-2001-2004/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-30l-v6-avk) . End diagnosis and switch ignition off.

See also:
• READINESS CODE, GENERATING
• EMERGENCY BATTERY, SWITCHING OFF/ON
• CHECK MOTRONIC ENGINE CONTROL MODULE (ECM) POWER SUPPLY RELAY -J271 - AND ACTIVATION
• MODE 3: CHECK DTC MEMORY
• MODE 4: RESET/ERASE DIAGNOSTIC DATA
• OVERVIEW OF COMPONENT LOCATIONS
• CHECKING ACTIVATION OF POWER OUTPUT STAGES