4.2l v8 5v Generic Scan Tool, Engine Code(s): Bhf Audi S4 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.

Note. All manufacturers special tools as well as common tools may contain a manufacturer specific part number. These tools may be substituted with an equivalent aftermarket tool or are available for purchase through Audi. Manufacturers special tools as well as common tools that contain a manufacturer specific part number may be referenced in the test procedure illustrations showing the tool use or installation. If the manufacturer specific tool is not being used, an equivalent aftermarket tool may be installed in the same manner as the manufacturers special tool. The manufacturers test box Test Box 105 Pin VAG1598/42 is available for purchase or rental.

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/s4/b7-2004-2008/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL 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!

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 electrical, testing

Special tools, testers and auxiliary items required

1. Hand held remote control (jumper).
2. Multimeter.
3. Electrical connector test lead set.

Test conditions

1. Battery voltage 12.5 V.
2. Fuse S228 (position 28) OK
3. Fuel Pump (FP) Relay J17 OK.
4. Ignition switched off.

Test sequence

1. Open cover of fuse box at left side of instrument cluster.
2. Connect Hand held remote control (jumper) between right terminal of socket from fuse S228 and vehicle battery B+.
3. Press button of remote control.

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

If no operating noise can be heard

1. Remove the rear seat bench. --> «72 - SEAT - FRAMES»(/audi/s4/b7-2004-2008/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/s4/b7-2004-2008/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

Scheme 608

1. Remove right locking flange cover - arrows -.

Scheme 609

1. Disconnect the electrical harness connector - 1 - from the fuel delivery unit.

Scheme 610

1. Connect a multimeter between terminals 1 and 4 of the electrical harness connector and test for voltage.
2. Press switch of remote control.

Specified value: approx. battery voltage

If the specified value was not obtained

1. Check the wiring for a short circuit to Ground (GND) or an open circuit.
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If specified value is obtained, although no running-noise can be heard at pump

Scheme 611

1. Check if the electrical wiring between the flange and fuel pump is connected and has continuity

If no malfunction is detected in the wires, replace the fuel pump.

1. Install fuel delivery unit.

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End diagnosis and switch the ignition off.

Fuel Pump (FP) delivery quantity, checking

Special tools, testers and auxiliary items required

1. Hand held remote control (jumper).
2. Multimeter.
3. Electrical connector test lead set.
4. Fuel pressure test set (high pressure).

1. Measuring container, fuel-resistant.

Test conditions

1. Fuse S228 (position 28) OK
2. Fuel Pump (FP) Relay J17 OK.
3. Battery voltage 12.5 V
4. Fuel filter OK

1. Fuel tank at least 1 / 4 filled.
2. Fuel pressure regulator OK.
3. Ignition switched off.

Test sequence

1. Remove right locking flange cover - arrows -.

1. Disconnect the electrical harness connector - 1 - from the fuel delivery unit.
2. Connect a Hand held remote control (jumper) to terminal - 1 - of the fuel delivery unit and to vehicle battery (+).

1. Connect a jumper cable from an Electrical connector test lead set to terminal - 4 - of the fuel delivery unit and to vehicle Ground (GND).
2. Remove the fuel filler cap from fuel filler tube.

Scheme 612

1. Remove rear engine cover - arrows -.

Scheme 613

1. Disconnect fuel line - arrow - at distribution piece.

Scheme 614

1. Connect an assisting hose onto the disconnected fuel supply line and hold into a measuring container.
2. Press switch on remote control for 15 seconds.

Scheme 615

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

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

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. Fuel lines pinched.
2. Fuel filter clogged.
3. Fuel pump faulty.

Assembly is performed in reverse order of removal.

Evaporative Emissions (EVAP) System

For all EVAP system component locations and hose routing. Refer to --> 20 - FUEL SUPPLY SYSTEM

For the EVAP system hose routing. Refer to --> 20 - FUEL SUPPLY SYSTEM

For all EVAP 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.

Note. All manufacturers special tools as well as common tools may contain a manufacturer specific part number. These tools may be substituted with an equivalent aftermarket tool or are available for purchase through Audi. Manufacturers special tools as well as common tools that contain a manufacturer specific part number may be referenced in the test procedure illustrations showing the tool use or installation. If the manufacturer specific tool is not being used, an equivalent aftermarket tool may be installed in the same manner as the manufacturers special tool.

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 scan tool.
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. Ensure the fuel filler cap is properly installed on the fuel tank.
2. Check the fuel filler cap seal for damage. Replace if necessary.
3. Remove the rear seatbench. --> «72 - SEAT - FRAMES»(/audi/s4/b7-2004-2008/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/s4/b7-2004-2008/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Remove right locking flange cover - arrows -.
2. Check 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. Check the line from the EVAP canister to the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.
2. Check the lines from the EVAP canister to the Leak Detection Pump (LDP) V144.
3. Check the line from the fuel tank to the EVAP canister (below cover for EVAP canister).
4. Check the lines for the tank ventilation (beneath right rear wheel housing liner).

1. Check the 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 leak is detected

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

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.
2. Wiring diagram.

Test requirements

1. The Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 Engine Electronics Fuse S282 OK.
2. The ignition switched off.

Note. Voltage for the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 is supplied via the Fuel Pump (FP) Relay J17.

Procedure

Scheme 616

1. Remove the right side engine compartment cover - 1 -.

Scheme 617

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

Checking internal resistance

1. Using a Multimeter , check the resistance between terminals 1 and 2 of the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.

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

If the specified value was not obtained

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

If the specification is obtained

Checking voltage supply

Scheme 618

1. Using a Multimeter , check the electrical harness connector terminal 1 to 2 for voltage.
2. Operate the starter briefly.

Specified value: battery voltage.

If the specified value was not obtained

1. Using a Multimeter , check the electrical harness connector terminal 1 to Ground (GND) for voltage.

1. Operate the starter briefly.

Specified value: battery voltage.

If the specified value was not obtained

1. Check the wiring connection from the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 electrical harness connector terminal 1 to the Fuel Pump (FP) Relay J17 terminal 2 for an open circuit or short to ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the wiring connection.

If the specified value was obtained

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

1. Using a Multimeter , check the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 electrical connector terminal 2 to the Engine Control Module (ECM) J623 electrical connector T121 terminal 64 for an open circuit.

Specified value: 1.5 ohms.

If the specification was not obtained

1. Check the wiring for a short circuit to Battery positive (+) or an open circuit.
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the wiring connection.

If the specification was obtained

1. Replace the Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End diagnosis and switch the ignition off.

Leak Detection Pump (LDP) V144 , checking

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Leak Detection Pump (LDP) V144 Engine Electronics Fuse S282 OK.
2. The ignition switched off.

Note. The voltage for the Leak Detection Pump (LDP) -V144- is supplied via the Fuel Pump (FP) Relay J17.

Procedure

1. Remove the left rear wheel housing liner. --> «66 EXTERIOR EQUIPMENT»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

Scheme 619

1. Disconnect the Leak Detection Pump (LDP) V144 electrical harness connector.

Checking internal resistance

Scheme 620

1. Using a Multimeter , check the Leak Detection Pump (LDP) V144 for resistance as follows

If any of the specifications were not obtained

1. Replace the Leak Detection Pump (LDP) -V144-. --> «20 - FUEL SUPPLY SYSTEM»(/audi/s4/b7-2004-2008/remont/fuel-system/#fuel-supply-system) .

If the specified values were obtained

Checking voltage supply

Scheme 621

1. Using a Multimeter , check the Leak Detection Pump (LDP) -V144- electrical harness connector terminal 3 to Ground (GND) for voltage.

1. Operate the starter briefly.

Specified value: battery voltage.

1. Switch the ignition off.

If the specified value was not obtained

1. Check the wiring for a short circuit to Ground (GND) or an open circuit.
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

It the specification was obtained.

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

1. Using a Multimeter , check the Leak Detection Pump (LDP) -V144- electrical harness connector terminals to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminals for an open circuit.

Specified value: 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. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the wiring connection.

If no malfunction is found in wiring

1. Replace the Motronic Engine Control Module (ECM) J623.

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

1. Install the right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/s4/b7-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/s4/b7-2004-2008/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 following sequence

1. Check the DTC memory.
2. If necessary, erase the DTC memory. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Function of "EPC" system

For "EPC" , the throttle valve is not operated by a cable from the accelerator pedal. There is no mechanical connection between the accelerator pedal and the throttle valve.

The position of the accelerator pedal is communicated to Motronic Engine Control Module (ECM) J623 via Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185 (variable resistances; stored in one housing) that are connected with the accelerator pedal.

The accelerator pedal position (drivers intention) is a main input unit for the Motronic Engine Control Module (ECM) J623.

Operation of the throttle valve occurs via an electric motor (Throttle Drive (for Electronic Power Control (EPC)) G186 ) in the Throttle Valve Control Module J338. This is true across the entire engine speed and engine load spectrum.

Throttle valve is operated by Throttle Drive (for Electronic Power Control (EPC)) G186 according to specifications of Motronic Engine Control Module (ECM) J623.

With engine off and ignition switched on, Motronic Engine Control Module (ECM) J623 controls the Throttle Drive (for Electronic Power Control (EPC)) G186 exactly according to specifications of Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185. This means, if the accelerator pedal is depressed half way, the Throttle Drive (for Electronic Power Control (EPC)) G186 opens the throttle valve to the same degree; i.e. throttle valve is then opened approx. half way.

With engine running (under load), Motronic Engine Control Module (ECM) J623 can open or close the throttle valve independently of Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185.

This means, for example, that the throttle valve could be fully opened even though the accelerator pedal has only been depressed half way. This has the advantage of preventing torque losses at the throttle valve.

In addition to this, it results in significantly better values relative to emissions and consumption under certain load conditions.

It would be incorrect to think that "EPC" consists of only one or two components. "EPC" is much more of a system containing all components that contribute to recognizing, controlling and monitoring the position of the throttle valve.

1. Observe safety precautions.
2. Observe rules for cleanliness.

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

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram

Test requirement

1. The Motronic Engine Control Module (ECM) J623 fuses 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.

Note. Use only gold-plated terminals when servicing the electrical harness connector terminals in Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185.

Test sequence

1. Remove the drivers side storage compartment. Refer to --> «68 - INTERIOR EQUIPMENT»(/audi/s4/b7-2004-2008/remont/gauges-instrument-panels/#body-interior) «68 - INTERIOR EQUIPMENT»(/audi/s4/b7-2004-2008/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

Scheme 622

1. Disconnect the Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185 6-pin electrical harness connector - 2 -.

Checking voltage supply and wiring

1. Switch the ignition on.

Scheme 623

1. Using a Multimeter , check the following wiring connections for voltage.

1. Switch the ignition off.

If the specification is not obtained

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .
2. Using a Multimeter , check the Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185 6-pin electrical harness connector terminals to the Motronic Engine Control Module (ECM) J623 electrical connector T121 for an open circuit according to wiring diagram.

Specified value: 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

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

1. Replace the Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185. --> «20 - FUEL SUPPLY SYSTEM»(/audi/s4/b7-2004-2008/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 Motronic Engine Control Module (ECM) J623.
2. Install the drivers side storage compartment. Refer to --> «68 - INTERIOR EQUIPMENT»(/audi/s4/b7-2004-2008/remont/gauges-instrument-panels/#body-interior) «68 - INTERIOR EQUIPMENT»(/audi/s4/b7-2004-2008/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 following sequence

1. Check the DTC memory.
2. If necessary, erase the DTC memory. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

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.

Note. All manufacturers special tools as well as common tools may contain a manufacturer specific part number. These tools may be substituted with an equivalent aftermarket tool or are available for purchase through Audi. . Manufacturers special tools as well as common tools that contain a manufacturer specific part number may be referenced in the test procedure illustrations showing the tool use or installation. If the manufacturer specific tool is not being used, an equivalent aftermarket tool may be installed in the same manner as the manufacturers special tool. The manufacturers test box Test Box 105 Pin VAG1598/42 is available for purchase or rental. .

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

Rules of cleanliness

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 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.
2. Separated electrical connectors: Protect from dirt and moisture. Make sure connections are dry when reconnecting.

Technical data

Oxygen Sensor (O2S) Heater Z19 f and Oxygen Sensor (O2S) 2 Heater Z28 before catalytic converter, checking.

The following procedure is used to diagnose Oxygen Sensor (O2S) Heater Z19 and Oxygen Sensor (O2S) 2 Heater Z28.

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

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Oxygen Sensor (O2S) Heater Z19 and Oxygen Sensor (O2S) 2 Heater Z28 Engine Electronics Fuse S282 OK.
2. The Fuel Pump (FP) Relay J17 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 for accessing Oxygen Sensor (O2S) 2 Heater Z28 electrical harness.

Scheme 624

1. Remove the left side engine compartment cover - 1 -.
2. Remove the coolant expansion tank screw - arrow -.

Scheme 625

1. Disconnect the electrical connector from the Engine Coolant Level (ECL) Warning Switch F66 and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

Scheme 626

1. Disconnect the Oxygen Sensor (O2S) 2 Heater Z28 for Heated Oxygen Sensor (HO2S) 2 G108 electrical harness connector - 4 -.

Procedure for accessing Oxygen Sensor (O2S) Heater Z19 electrical harness.

1. Remove the cover on the right side of the engine compartment - 1 -.

Scheme 627

1. Remove the air intake duct - arrows -.

Scheme 628

1. Disconnect the Oxygen Sensor (O2S) Heater Z19 for Heated Oxygen Sensor (HO2S) G39 electrical harness connector - 1 -.

Checking internal resistance

1. Using a multimeter , check the Heated Oxygen Sensor (HO2S) terminals 6 to 3 for an open circuit.

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

If the specification was not obtained

1. Replace the Heated Oxygen Sensor (HO2S) G39 or the Heated Oxygen Sensor (HO2S) 2 G108 --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the specification was obtained

Checking voltage supply

Scheme 629

1. Using a multimeter , check the Heated Oxygen Sensor (HO2S) electrical harness connector terminal 3 to ground (GND) for voltage.

Specified value: Battery voltage.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If the specification was obtained

Checking Ground (GND) activation

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .
2. Using a multimeter , check the Heated Oxygen Sensor (HO2S) electrical harness connector to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 for an open circuit.

Specified value: 1.5 ohms max.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. 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 Motronic Engine Control Module (ECM) J623.
2. Install the engine cover with air filter --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater Z29 and Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater Z30 , checking

The following procedure is used to diagnose Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater Z29 and Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater Z30.

Note. When servicing terminals in harness connector of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 , use only gold-plated terminals.

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 Engine Electronics Fuse S282 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 for accessing Oxygen Sensor (O2S) 2 Heater Z30 electrical harness.

1. Remove the left side engine compartment cover - 1 -.
2. Remove the coolant expansion tank screw - arrow -.

1. Disconnect the electrical connector from the Engine Coolant Level (ECL) Warning Switch F66 and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

1. Disconnect the Oxygen Sensor (O2S) 2 Heater Z30 for Heated Oxygen Sensor (HO2S) 2 G108 electrical harness connector - 1 -.

Procedure for accessing Oxygen Sensor (O2S) Heater Z29 electrical harness.

1. Remove the cover on the right side of the engine compartment - 1 -.

1. Remove the air intake duct - arrows -.

1. Disconnect the Oxygen Sensor (O2S) Heater Z29 for Heated Oxygen Sensor (HO2S) G39 electrical harness connector - 4 -.

Checking internal resistance

1. Using a multimeter , check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) terminals 1 to 2 for resistance.

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

If the specification was not obtained

1. Replace the faulty Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If the specification was obtained

Checking voltage supply

1. Using a multimeter , check the Heated Oxygen Sensor (HO2S) electrical harness connector terminal 1 to ground (GND) for voltage.

Specified value: Battery voltage.

If the specification was not obtained

1. Check the Heated Oxygen Sensor (HO2S) electrical harness connector terminal 1 to the Fuel Pump (FP) Relay J17 terminal 2 for an open circuit.
2. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
3. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
4. If necessary, repair the faulty wiring connection.

If the specification was obtained

Checking Ground (GND) activation

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

1. Using a multimeter , check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) electrical harness connector to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 for an open circuit.

Specified value: 1.5 ohms max.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. 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 Motronic Engine Control Module (ECM) J623.

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Mass Air Flow (MAF) Sensor G70 , checking

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

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Mass Air Flow (MAF) Sensor G70 Engine Electronics Fuse S282 OK.
2. The Fuel Pump (FP) Relay J17 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. Coolant Temperature at least 80°C.

1. Ignition switched off.

Function test

1. Connect the scan tool.
2. Start engine and let it run at idle.
3. Using the scan tool, Check the air flow quantity of the Mass Air Flow (MAF) Sensor G70 at idle

1. End diagnosis and switch ignition off.

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

1. Check the voltage supply of the Mass Air Flow (MAF) Sensor G70.

If specified value was not obtained

1. Check the wiring of the Mass Air Flow (MAF) Sensor G70.

Checking voltage supply

Scheme 630

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

1. Using a multimeter , check the Mass Air Flow (MAF) Sensor G70 electrical harness connector terminal 3 to engine Ground (GND).

Specified value: battery voltage.

1. Switch the ignition off.

If specified value was not obtained

1. Check the Mass Air Flow (MAF) Sensor G70 electrical harness connector terminal 2 to the Fuel Pump (FP) Relay J17 terminal 2 for an open circuit.

Specified value: 1.5 ohms max.

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

Checking electrical circuit

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

1. Using a multimeter , check the Mass Air Flow (MAF) Sensor G70 electrical harness connector terminals to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminals for an open circuit.

Specified value: 1.5 ohms max.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

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

1. Replace Mass Air Flow (MAF) Sensor G70 --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Throttle Valve Control Module J338 , checking

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

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) J623 Fuse S243 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 Throttle Valve Control Module J338. It is operated by Motronic Engine Control Module (ECM) J623 according to specifications of 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 scan tool.
2. Switch ignition on.
3. Using the scan tool, check the throttle valve position (absolute) at idle stop

1. Slowly depress the accelerator pedal to Wide Open Throttle (WOT) stop while observing the percentage display. The percentage display must increase uniformly.
2. Using the scan tool, check the throttle valve position (absolute) at Wide Open Throttle (WOT) stop

1. End diagnosis and switch ignition off.

If the specified values are not obtained

Scheme 631

1. Remove the rear engine cover - arrows -.
2. Remove the Throttle Valve Control Module J338 far enough so that the electrical connector terminals are reached.

Scheme 632

1. Disconnect the Throttle Valve Control Module J338 electrical harness connector - 6 -.

Checking resistance

1. Using a multimeter , check the Throttle Drive (for Electronic Power Control (EPC)) G186 at the Throttle Valve Control Module J338 terminals 3 to 5 for resistance.

Specified value: 1.0 to 5.0 ohms (at 20°C)

If the specification was not obtained

1. Replace the Throttle Valve Control Module J338 --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the specification was obtained

1. Check the voltage supply of the Throttle Valve Control Module J338 to the Motronic Engine Control Module (ECM) J623 «Checking voltage supply and wiring»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__checking-voltage-supply-and-wiring) .

Checking voltage supply and wiring

1. Switch the ignition on.

Scheme 633

1. Using a Multimeter , check the Throttle Drive (for Electronic Power Control (EPC)) G186 at the Throttle Valve Control Module J338 electrical harness connector terminals 2 to 6 for voltage.

Specified value: at least 4.5 V

1. Switch the ignition off.

If the specification was not obtained

Scheme 634

1. Using a Multimeter , check the Throttle Drive (for Electronic Power Control (EPC)) G186 at Throttle Valve Control Module J338 electrical harness connector terminals to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminals for an open circuit.

Specified value: 1.5 ohms max.

If the specification is not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. If necessary, repair the faulty wiring connection.
3. Check the electrical harness connector for damage, corrosion, lose or broken terminals.

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

1. Replace Motronic Engine Control Module (ECM) J623.

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Engine Coolant Temperature (ECT) Sensor G62 , checking

Note. This procedure is used to diagnose the 2 pin Engine Coolant Temperature (ECT) Sensor G62 from June 2005. To diagnose the 4 pin Engine Coolant Temperature (ECT) Sensor G62 Phased in modification, Refer to Engine Coolant Temperature (ECT) Sensor G62 , checking .

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

Special tools, testers and auxiliary items required

1. Multimeter.
2. Jumper wire.
3. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) J623 Fuse S243 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 scan tool.
2. Switch the ignition on.
3. Using the scan tool, check the coolant temperature

If the specified value is not obtained

1. Continue test according to the following table

If the specified value was obtained

1. Start the engine and let it run at idle.

The 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 the Engine Coolant Temperature (ECT) Sensor G62 --> «19 - ENGINE - COOLING SYSTEM»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

Checking internal resistance

Scheme 635

1. Disconnect the Engine Coolant Temperature (ECT) Sensor G62 electrical harness connector - 2 -.

Scheme 636

1. Using a multimeter , check the Engine Coolant Temperature (ECT) Sensor G62 terminals 1 to 2 for resistance.

Use the chart below for the specified values

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

Scheme 637

Specified values

1. Range A, 30°C equals a resistance of 1.5 to 2.0 kohms
2. Range B, 80°C equals a resistance of 275 to 375ohms

If any of the specified values was not obtained

1. Replace the Engine Coolant Temperature (ECT) Sensor G62 --> «19 - ENGINE - COOLING SYSTEM»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

Testing if display is approx. - 40.0°C

1. Disconnect the Engine Coolant Temperature (ECT) Sensor G62 electrical harness connector - 1 -.
2. Using a jumper wire , connect the Engine Coolant Temperature (ECT) Sensor G62 electrical harness connector terminals 1 to 2.
3. Check the value indicated on the scan tool display.

If the value jumps to approx. 140.0°C

1. End diagnosis and switch the ignition off.
2. Replace the Engine Coolant Temperature (ECT) Sensor G622 --> «19 - ENGINE - COOLING SYSTEM»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If indication remains at approx. -40.0°C

Testing if display approx. 140.0°C

1. Disconnect the Engine Coolant Temperature (ECT) Sensor G62 electrical harness connector - 2 -.

If indication jumps to approx. -40.0°C

1. End diagnosis and switch ignition off.
2. Replace the Engine Coolant Temperature (ECT) Sensor G62 --> «19 - ENGINE - COOLING SYSTEM»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If indication remains at approx. 140.0°C

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

1. Using a Multimeter , check the Engine Coolant Temperature (ECT) Sensor G62 electrical harness connector terminals to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminals for an open circuit according to the wiring diagram.

Specified value: 1.5 ohms Max.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

1. Replace the Motronic Engine Control Module (ECM) J623.

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Note. This procedure is used to diagnose the 4 pin Engine Coolant Temperature (ECT) Sensor G62 Phased in modification. Refer to --> Engine Coolant Temperature (ECT) Sensor G62 , checking Engine Coolant Temperature (ECT) Sensor G62 for 2 pin from June 2005 diagnosis.

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

Special tools, testers and auxiliary items required

1. Multimeter.
2. Jumper wire.
3. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) J623 Fuse S243 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 scan tool.
2. Switch the ignition on.
3. Using the scan tool, check the coolant temperature

If the specified value is not obtained

1. Continue test according to the following table

If the specified value was obtained

1. Start the engine and let it run at idle.

The 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 the Engine Coolant Temperature (ECT) Sensor G62 --> «19 - ENGINE - COOLING SYSTEM»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

Checking internal resistance

1. Disconnect the Engine Coolant Temperature (ECT) Sensor G62 electrical harness connector - 2 -.

Scheme 638

1. Using a multimeter , check the Engine Coolant Temperature (ECT) Sensor G62 terminals 3 to 4 for resistance.

Use the chart below for the specified values

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

Specified values

1. Range A, 30°C equals a resistance of 1.5 to 2.0 kohms
2. Range B, 80°C equals a resistance of 275 to 375ohms

If any of the specified values was not obtained

1. Replace the Engine Coolant Temperature (ECT) Sensor G62 --> «19 - ENGINE - COOLING SYSTEM»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

Scheme 639

1. Disconnect the Engine Coolant Temperature (ECT) Sensor G62 electrical harness connector - 1 -.
2. Using a jumper wire , connect the Engine Coolant Temperature (ECT) Sensor G62 electrical harness connector terminals 3 to 4.
3. Check the value indicated on the scan tool display.

If the value jumps to approx. 140.0°C

1. End diagnosis and switch the ignition off.
2. Replace the Engine Coolant Temperature (ECT) Sensor G622 --> «19 - ENGINE - COOLING SYSTEM»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If indication remains at approx. -40.0°C

1. Disconnect the Engine Coolant Temperature (ECT) Sensor G62 electrical harness connector - 2 -.

If indication jumps to approx. -40.0°C

1. End diagnosis and switch ignition off.
2. Replace the Engine Coolant Temperature (ECT) Sensor G62 --> «19 - ENGINE - COOLING SYSTEM»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If indication remains at approx. 140.0°C

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

1. Using a Multimeter , check the Engine Coolant Temperature (ECT) Sensor G62 electrical harness connector terminals to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminals for an open circuit according to the wiring diagram.

Specified value: 1.5 ohms Max.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

1. Replace the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Engine Speed (RPM) Sensor G28 , checking

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

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) J623 Fuse S243 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 scan tool.
2. Switch the ignition on.
3. Using the scan tool, check the engine speed

1. End diagnosis and switch ignition off.

If the specified value was not obtained

Checking internal resistance

1. Remove the left side engine compartment cover - 1 -.
2. Remove the coolant expansion tank screw - arrow -.

1. Disconnect the electrical connector from the Engine Coolant Level (ECL) Warning Switch F66 and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

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

Scheme 640

1. Using a multimeter , check the Engine Speed (RPM) Sensor G28 terminals 2 to 3 - B - for resistance.

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

1. Check Engine Speed (RPM) Sensor G28 terminals 1 to 2 and 1 to 3 for short circuits.

Specified value: infinity (infinity)

If any of the specified values are not obtained

1. Replace the Engine Speed (RPM) Sensor G28 --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If the specified values are obtained

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

1. Using a Multimeter , check the Engine Speed (RPM) Sensor G28 electrical harness connector terminals to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminals for an open circuit.

Specified value: 1.5 ohms Max.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

1. Remove the Engine Speed (RPM) Sensor G28 and check the sensor wheel for proper seating, damage and run-out --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If the sensor wheel is OK

1. Replace the Motronic Engine Control Module (ECM) J623.
2. If sensor wheel not okay, replace Engine Speed (RPM) Sensor G28

> 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Fuel Injectors N30, N31, N32, N33, N83, N84, N85, N86 , checking

The following test procedure is used to diagnose all fuel injectors.

Electrical test

Special tools, testers and auxiliary items required

1. Multimeter.
2. Diode test lamp (12V).
3. Wiring diagram.

Test requirements

1. The Fuel Injectors N30, N31, N32, N33, N83, N84, N85, N86 S116 OK.
2. The Engine Speed (RPM) Sensor G28 OK, checking.
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.

1. Observe safety precautions.
2. Observe rules for cleanliness.

Procedure

1. Remove the engine cover with air filter --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .
2. Disconnect the Fuel Injector electrical harness connectors from Fuel Injectors N30, N31, N32, N33, N83, N84, N85, N86.

Checking internal resistance

Scheme 641

1. Using a multimeter , check the Fuel Injector electrical terminals 1 to 2 for resistance.

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

If the specified value was not obtained

1. Replace the malfunctioning Fuel Injector --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the specified value was obtained

Checking activation and wiring

Scheme 642

1. Connect a diode test lamp (12V) to the electrical harness connector terminals 1 and 2 of the Fuel Injector to be tested.
2. Operate the starter and test the activation of the Fuel Injector.

LED should flicker.

1. Switch the ignition off.

If LED does not flicker

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

Scheme 643

1. Using a Multimeter , check the Fuel Injector electrical harness connector terminals to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminals for an open circuit.

Specified value: 1.5 ohms Max.

If the specification is not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

1. Replace the Motronic Engine Control Module (ECM) J623.
2. Install the engine cover with air filter --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Heated Oxygen Sensor (HO2S) G39/Heated Oxygen Sensor (HO2S) 2 G108 and oxygen sensor regulation before catalytic converter, checking

The following procedure is used to diagnose both Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 2 G108

Note. Use only gold-plated terminals when servicing terminals in the electrical harness connectors of the Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 2 G108.

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) 2 Heater Z28 Engine Electronics Fuse S282 OK.
2. The Oxygen Sensor (O2S) Heater Z19 and Oxygen Sensor (O2S) 2 Heater Z28 before catalytic converter OK. Refer to --> «Oxygen Sensor (O2S) Heater Z19 f and Oxygen Sensor (O2S) 2 Heater Z28 before catalytic converter, checking.»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__oxygen-sensor-o2s-heater-z19-f) .
3. The Fuel Pump (FP) Relay J17 OK.
4. Battery voltage at least 12.5 volts.

1. All electrical consumers such as, lights and rear window defroster, switched off.
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 scan tool.
2. Start the 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".
2. Check the specified values at idle.

If specified values are obtained

1. End diagnosis and switch the ignition off.

If the specified values are not obtained

Procedure for accessing the Heated Oxygen Sensor (HO2S) 2 G108 electrical harness.

1. Remove the left side engine compartment cover - 1 -.
2. Remove the coolant expansion tank screw - arrow -.

1. Disconnect the electrical connector from the Engine Coolant Level (ECL) Warning Switch F66 and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

1. Disconnect the Heated Oxygen Sensor (HO2S) 2 G108 electrical harness connector - 4 -.

Procedure for accessing the Heated Oxygen Sensor (HO2S) G39 electrical harness.

1. Remove the cover on the right side of the engine compartment - 1 -.

1. Remove the air intake duct - arrows -.

1. Disconnect the Heated Oxygen Sensor (HO2S) G39 electrical harness connector - 1 -.

Checking primary voltage

1. Using a multimeter , check the Heated Oxygen Sensor (HO2S) electrical harness connector terminals 1 to 5 for voltage.

Specified value: 0.400 to 0.500 Volts

1. Switch the ignition off.

If the specified value was not obtained

1. Replace the Heated Oxygen Sensor (HO2S) G39 or the Heated Oxygen Sensor (HO2S) 2 G108 --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If the specified value was obtained

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

1. Using a Multimeter , check the Heated Oxygen Sensor (HO2S) G39 or the Heated Oxygen Sensor (HO2S) 2 G108 electrical harness connector terminals to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminals for an open circuit.

Specified value: 1.5 ohms Max.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

1. Replace the Motronic Engine Control Module (ECM) J623.

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130/Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 and oxygen sensor regulation behind catalytic converter, checking

The following procedure is used to diagnose both Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131

Note. Vehicle must be raised before the electrical connector of the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 is accessible. When servicing terminals 3 and 4 in the electrical harness connector of the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 , use only gold-plated terminals.

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 Engine Electronics Fuse S282 OK.
2. Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater Z29 and Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater Z30 OK. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .
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 scan tool.
2. Start the 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-IDs.
2. Check the specified values at idle.

If the specified values are obtained

1. End diagnosis and switch ignition off.

If the specified values are not obtained

Procedure for accessing the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 electrical harness.

1. Remove the left side engine compartment cover - 1 -.
2. Remove the coolant expansion tank screw - arrow -.

1. Disconnect the electrical connector from the Engine Coolant Level (ECL) Warning Switch F66 and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

1. Disconnect the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 electrical harness connector - 1 -.

Procedure for accessing the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 electrical harness.

1. Remove the cover on the right side of the engine compartment - 1 -.

1. Remove the air intake duct - arrows -.

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

Checking primary voltage

1. Switch the ignition on.

1. Using a multimeter , check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 electrical harness connector terminals 3 to 4 for voltage.

Specified value: 0.400 to 0.500 Volts

1. Switch the ignition off.

If the specified value was obtained

1. Replace the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 or Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If the specified value was not obtained

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

1. Using a Multimeter , check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 electrical harness connector terminals to the Motronic Engine Control Module (ECM) J623 or Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 electrical harness connector T121 terminals for an open circuit.

Specified value: 1.5 ohms Max.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

1. Replace the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Function

Motronic Engine Control Module (ECM) J623 regulates fuel injection, Throttle Valve Control Module J338 , oxygen sensor regulation, ignition, knock control, Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 , engine speed limitation through fuel injectors or Fuel Pump (FP) Relay J17 as well as On Board Diagnostic (OBD).

Voltage supply, checking

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) J623 fuses 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, 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 the Motronic Engine Control Module (ECM) Power Supply Relay J271.

Checking voltage

1. Using a Multimeter , check the Motronic Engine Control Module (ECM) Power Supply Relay J271 socket 30 to Ground (GND).

Specified value: battery voltage.

If the specified value was not obtained

1. Check the wiring connections from the Battery to the Motronic Engine Control Module (ECM) Power Supply Relay J271 socket 30 for an open circuit or a short circuit.
2. Check the wiring connections for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If the specified value was obtained

1. Switch the ignition on.
2. Using a Multimeter , check the Motronic Engine Control Module (ECM) Power Supply Relay J271 socket 87 to Ground (GND).

Specified value: battery voltage.

If the specified value was obtained

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .
2. Using a Multimeter , check the Motronic Engine Control Module (ECM) Power Supply Relay J271 socket 86 to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminal 23 for resistance.
3. Ensure key is off

Specified value: 2.0 ohms Max.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

Checking activation

1. Re-install Motronic Engine Control Module (ECM) Power Supply Relay J271
2. Switch the ignition on.
3. Using a Multimeter , check the Motronic Engine Control Module (ECM) Power Supply Relay J271 socket 86 to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminal 23 for voltage.

1. Switch the ignition off.

Specified value: 0.5 V Max.

If the specified value was obtained

1. Replace the Motronic Engine Control Module (ECM) Power Supply Relay J271 : --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the specified value was not obtained

1. Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
2. Check the wiring connection for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

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

1. Replace the Motronic Engine Control Module (ECM) J623.

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Motronic Engine Control Module (ECM) J623 , replacing

Removing

Special tools, testers and auxiliary items required

1. Heat gun.

Note. When the Motronic Engine Control Module (ECM) J623 electrical harness connectors are disconnected, the adaptation values are erased and the DTC memory content remains intact.

Work procedure

Check the identification of the previous Motronic Engine Control Module (ECM) J623 as follows

1. Connect the scan tool.
2. Switch the ignition on.
3. Using the scan tool, select "Vehicle information".
4. Select " Calibration Identification" in vehicle information.

The electronic control module identification number will be displayed, e.g.: 06A906032NA 4983

1. Record the electronic control module identification number.
2. End diagnosis and switch the ignition off.

Procedure

1. Switch the ignition on.
2. Actuate the touch-wipe function to allow the wipers to move to the end position.

Note. The wiper arms will now move into the line of view on the windshield (service position).

1. Remove the rubber seal of plenum chamber cover in direction of - arrow -.

Scheme 644

1. Remove the plenum chamber cover - 1 - toward front.
2. Remove the wiper arms caps - 3 -.
3. Loosen the wiper arm nuts - 4 - several turns.
4. Loosen the wiper arms from the wiper axle by rocking slightly.

Scheme 645

1. Remove the wiper arms nuts and the wiper arms from the wiper axles.

Scheme 646

1. Remove the plenum chamber cover screws - arrows -.

Scheme 647

1. Remove the Engine Control Module (ECM) retaining bracket using a screwdriver.

Note. The threads of the shear bolts have been coated with a locking compound and must be heated to be removed.

Scheme 648

The Motronic Engine Control Module (ECM) J623 is secured via a protective housing - 4 - and shear bolts - 3

Scheme 649

1. Using a Heat gun set at its lowest setting, heat the shear bolt for approx. 20 to 25 seconds.

Scheme 650

1. Remove the shear bolt with locking pliers. Discard the used shear bolts.

Repeat the previous steps for the second shear bolt.

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

Scheme 651

1. Remove the front electrical harness connector - 1 - and - 2 - from the Motronic Engine Control Module (ECM) J623.

Motronic Engine Control Module (ECM) J623 installation

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

The Motronic Engine Control Module (ECM) J623 must be installed with the protective housing.

Use New shear bolts when installing the Motronic Engine Control Module (ECM) J623.

Motronic Engine Control Module (ECM) J623 reprogramming

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 following sequence

1. Check the DTC memory.
2. If necessary, erase the DTC memory. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

CAN-Bus terminal resistance, checking

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirement

1. A CAN-Bus malfunction was recognized.
2. The Motronic Engine Control Module (ECM) J623 fuses 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.

Function

The Motronic Engine Control Module (ECM) J623 communicates with other CAN-Bus capable control modules.

The control modules are connected by two data bus wires which are twisted together (CAN_High and CAN_Low), and exchange information (messages). Missing information on the CAN-bus is recognized as a malfunction by the Motronic Engine Control Module (ECM) J623 and the other control modules connected to the CAN-bus.

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

Procedure

1. Disconnect the Data Bus On Board Diagnostic Interface T32b electrical harness connector.

Note. The Motronic Engine Control Module (ECM) J623 must remain connected for the following step.

1. Using a Multimeter , check the Instrument Cluster Control Module J285 electrical harness connector terminals 19 to 20 for resistance.

Specified value: 60 to 72 ohms (at approx. 20°C)

If the specified value was not obtained

1. Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
2. Check the wiring connection for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

1. Replace the Motronic Engine Control Module (ECM) J623.

If the specified value was obtained

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .
2. Using a Multimeter , check the Instrument Cluster Control Module J285 electrical harness connector to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 for resistance.

Specified value: 1.5 ohms Max.

If the specified value was not obtained

1. Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
2. Check the wiring connection for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

1. Replace the Instrument Cluster Control Module J285.

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Exhaust system components, removing and installing

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.

Note. All manufacturers special tools as well as common tools may contain a manufacturer specific part number. These tools may be substituted with an equivalent aftermarket tool or are available for purchase through Audi. . Manufacturers special tools as well as common tools that contain a manufacturer specific part number may be referenced in the test procedure illustrations showing the tool use or installation. If the manufacturer specific tool is not being used, an equivalent aftermarket tool may be installed in the same manner as the manufacturers special tool.

Three Way Catalytic Converter (TWC), checking

Function test

1. Connect the scan tool.
2. Start the engine and let it run at idle.
3. Select "Diagnostic mode 6: Check test results of components that are not continuously monitored".
4. Select "Catalytic converter monitoring".

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

1. End diagnosis and switch the ignition off.

If the specified values are exceeded

1. Replace the catalytic converter with front exhaust pipe --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Principle and function

Principle

Due to the rich mixture during the cold start phase, the exhaust emissions contain an increased level of unburned hydrocarbons. The Secondary Air Injection (AIR) system improves the secondary oxidation within the catalytic converter, thereby reducing harmful emissions. The heat released by secondary oxidation shortens the startup time of the catalytic converter considerably, as well as significantly improves emissions quality during the cold-running phase.

Function

1. During cold start (with coolant temperatures +15 to +35°C), the Secondary Air Injection (AIR) system blows air behind the exhaust valve for approx. 65 seconds. This produces an oxygen rich exhaust gas, causes the after burning and reduces the heating-up phase of the catalytic converter.
2. In addition, the Secondary Air Injection (AIR) system is switched on with a delay of approx. 20 seconds during idle for 5 seconds after every subsequent engine start up to max. 80°C coolant temperature and is checked via On Board Diagnostic (OBD).

Combination Valve for Secondary Air Injection (AIR), checking function and proper seal

The following procedure is used to test all combination valves.

Special tools, testers and auxiliary items required

1. Hand vacuum pump

Test conditions

1. Vacuum lines and hose connections free of leaks.
2. Vacuum lines not plugged.

Test sequence

1. Remove the rear engine cover

1. Remove the right engine compartment cover - 1 -.

1. Remove the air intake duct - arrows -.
2. Remove the vacuum hose from the combination valve.
3. Disconnect the Secondary Air Injection hose.

Scheme 652

1. Connect hand vacuum pump to combination valve vacuum connection.
2. Inject a light air pressure into the in Secondary Air Injection hose to close the combination valve. (do not use compressed air).

1. The combination valve should close and seal. Air should not be able to pass through the combination valve.

1. Operate the hand vacuum pump.

1. The combination valve should open. Air should be able to pass through the combination valve.

If combination valve does not open

1. Replace the faulty combination valve.

Secondary Air Injection (AIR) Pump Relay -J299- , checking

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Secondary Air Injection (AIR) Pump Fuse S130 OK.
2. The Motronic Engine Control Module (ECM) Power Supply Relay J271 fuse OK.
3. Battery voltage at least 12.5 V.
4. All electrical consumers switched off (radiator fan must NOT run during test).

1. A/C switched off.
2. The ignition switched off.

Procedure

1. Remove the Secondary Air Injection (AIR) Pump Relay -J299-.

Checking voltage

1. Using a Multimeter , check the Secondary Air Injection (AIR) Pump Relay -J299- socket 87 to Ground (GND).

Specified value: battery voltage.

If the specified value was not obtained

1. Check the wiring connections from the Battery to the Secondary Air Injection (AIR) Pump Relay -J299- socket 87 for an open circuit or a short circuit.
2. Check the wiring connections for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If the specified value was obtained

1. Switch the ignition on.
2. Using a Multimeter , check the Motronic Engine Control Module (ECM) Power Supply Relay J271 socket 87 to the Secondary Air Injection (AIR) Pump Relay -J299- socket 85 for voltage.
3. Switch the ignition off.

Specified value: battery voltage.

If the specified value was not obtained

1. Check the wiring connections from the Motronic Engine Control Module (ECM) Power Supply Relay J271 socket 87 to the Secondary Air Injection (AIR) Pump Relay -J299- socket 25 for an open circuit or a short circuit.
2. Check the wiring connections for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking activation

1. Switch the ignition on.
2. Using a Multimeter , check the Secondary Air Injection (AIR) Pump Relay -J299- socket 2/24 to Ground (GND)
3. Switch the ignition off.

Specified value: battery voltage.

If the specified value was not obtained

1. Check the wiring connection from the Secondary Air Injection (AIR) Pump Relay -J299- socket 85 to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminal 49 for an open circuit or a short circuit.
2. Check the wiring connections for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) (test box) at Engine Control Module.

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .
2. Using a Multimeter , check the Secondary Air Injection (AIR) Pump Relay -J299- socket 85 to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 terminal 46 for resistance.

Specified value: 1.5 ohms Max.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

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

1. Replace the Secondary Air Injection (AIR) Pump Relay -J299-. Refer to --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

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

1. Replace the Motronic Engine Control Module (ECM) J623.

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Secondary Air Injection (AIR) Pump Motor -V101- , checking

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Secondary Air Injection (AIR) Pump Relay -J299- fuses OK.
2. The Motronic Engine Control Module (ECM) Power Supply Relay J271 fuse OK.
3. Battery voltage at least 12.5 V.
4. All electrical consumers switched off (radiator fan must NOT run during test).

1. A/C switched off.
2. The ignition switched off.

Procedure

Scheme 653

1. Disconnect the secondary air injection hose - arrow -.

Scheme 654

1. Remove the sound insulator quick-release fasteners - 1 - , and screws - 2 -.

Scheme 655

1. Disconnect the Secondary Air Injection (AIR) Pump Motor -V101- electrical harness connector - 1 -.

Checking voltage

1. Switch the ignition on.

Scheme 656

1. Using a Multimeter , check the Secondary Air Injection (AIR) Pump Motor -V101- electrical harness connector terminals 1 to 2 for voltage.
2. Switch the ignition off.

Specified value: battery voltage.

If the specified value was not obtained

1. Using a Multimeter , check the Secondary Air Injection (AIR) Pump Motor -V101- electrical harness connector terminal 2 to Ground (GND).

Specified value: battery voltage.

If the specified value was not obtained

1. Check the wiring connection from the Secondary Air Injection (AIR) Pump Relay -J299- socket 87 to the Secondary Air Injection (AIR) Pump Motor -V101- electrical harness connector terminal 2 for an open circuit or a short circuit.
2. Check the wiring connections for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking Ground (GND)

1. Using a Multimeter , check the Secondary Air Injection (AIR) Pump Motor -V101- electrical harness connector terminal 1 to Ground (GND) for resistance.

Specified value: 1.5 ohms Max.

If the specification was not obtained

1. Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
2. Check the electrical harness connector for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

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

1. Replace Secondary Air Injection (AIR) Pump Motor -V101-.

1. Install the sound insulator quick-release fasteners - 1 - , and screws - 2 -.

1. Connect the secondary air injection hose - arrow -.

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

General notes on ignition system

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.

Note. All manufacturers special tools as well as common tools may contain a manufacturer specific part number. These tools may be substituted with an equivalent aftermarket tool or are available for purchase through Audi. . Manufacturers special tools as well as common tools that contain a manufacturer specific part number may be referenced in the test procedure illustrations showing the tool use or installation. If the manufacturer specific tool is not being used, an equivalent aftermarket tool may be installed in the same manner as the manufacturers special tool. The manufacturers test box Test Box 105 Pin VAG1598/42 is available for purchase or rental. .

If engine is to be cranked at starting RPM without starting, e.g. for a compression test

Scheme 657

1. Remove Fuse 6 (on fuse panel B) SB6 and Fuse 29 (on fuse panel B) SB29 from the fuse holder, E-box, plenum chamber.

By removing Fuse 6 (on fuse panel B) SB6, voltage supply of Ignition Coils with Power Output Stage N70, N127, N291, N292, N323, N324, N325, N326 is interrupted, that of Fuel Injectors N30, N31, N32, N33, N83, N84, N85, N86 by removing Fuse 29 (on fuse panel B) SB29.

Test Data, Spark Plugs

Camshaft Position (CMP) Sensor G40 and Camshaft Position (CMP) Sensor 2 G163 , checking

The following procedure is used to diagnose both Camshaft Position (CMP) Sensor G40 and Camshaft Position (CMP) Sensor 2 G163

Note. Use only gold-plated terminals when servicing terminals in harness connectors of Camshaft Position (CMP) Sensor G40 and Camshaft Position (CMP) Sensor 2 G163.

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) J623 fuses 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 the engine cover with air filter --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

Scheme 658

1. Disconnect the Camshaft Position (CMP) Sensor G40 electrical harness connector - 1 - or Camshaft Position (CMP) Sensor 2 G163.
2. Switch the ignition on.

Scheme 659

1. Using a Multimeter , Check the Camshaft Position (CMP) Sensor G40 or Camshaft Position (CMP) Sensor 2 G163 electrical harness connector terminals 1 to 3 for voltage.

Specified value: about 5.0 V

1. Switch the ignition off.

If the specification was not obtained

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623)

Scheme 660

1. Using a Multimeter , Check the Camshaft Position (CMP) Sensor G40 or Camshaft Position (CMP) Sensor 2 G163 electrical harness connector to the Motronic Engine Control Module (ECM) electrical harness connector T121 for an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was not obtained

1. Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
2. Check the wiring connection for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

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

1. Replace the Camshaft Position (CMP) Sensor G40 or Camshaft Position (CMP) Sensor 2 G163 --> «28 IGNITION/GLOW PLUG SYSTEM»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

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

1. Replace the Motronic Engine Control Module (ECM) J623.
2. Install the engine cover with air filter --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Camshaft Adjustment Valve 1 N205 and Camshaft Adjustment Valve 2 (exhaust) N208 , checking

The following procedure is used to diagnose both Camshaft Adjustment Valve 1 N205 and Camshaft Adjustment Valve 1 (exhaust) N208

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Camshaft Adjustment Valve 1 N205 fuse OK.
2. Motronic Engine Control Module (ECM) Power Supply Relay J271 OK, checking --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.
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 the engine cover with air filter --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

Scheme 661

1. Disconnect Camshaft Adjustment Valve 1 N205 electrical harness connector - 1 - or Camshaft Adjustment Valve 1 (exhaust) N208.

Scheme 662

1. Using a Multimeter , check the Camshaft Adjustment Valve 1 N205 or Camshaft Adjustment Valve 1 (exhaust) N208 for resistance.
2. Measure pin 1 pin 2 of the component.

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

If the specified value was not obtained

1. Replace the Camshaft Adjustment Valve 1 N205 or Camshaft Adjustment Valve 2 (exhaust) N208 --> «15 - ENGINE - CYLINDER HEAD, VALVETRAIN»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If the specified value was obtained

Checking voltage

1. Switch the ignition on.
2. Using a Multimeter , Check the Camshaft Adjustment Valve 1 N205 or Camshaft Adjustment Valve 2 (exhaust) N208 electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) Power Supply Relay J271 terminal 87/2 for voltage.
3. Switch the ignition off.

Specified value: battery voltage.

If the specified value was not obtained

1. Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
2. Check the wiring connection for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623)

1. Using a Multimeter , Check the Camshaft Adjustment Valve 1 N205 or Camshaft Adjustment Valve 2 (exhaust) N208 electrical harness connector terminal 2 to the Motronic Engine Control Module (ECM) electrical harness connector for an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was not obtained

1. Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
2. Check the wiring connection for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

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

1. Replace the Motronic Engine Control Module (ECM) J623.
2. Install the engine cover with air filter --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Knock Sensor (KS) 1 G61/Knock Sensor (KS) 2 G66/Knock Sensor 3 G198/Knock Sensor 4 G199 , checking

The following procedure is used to diagnose all Knock Sensors.

Special tools, testers and auxiliary items required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The mounting bolt of Knock Sensor (KS) 1 G61/Knock Sensor (KS) 2 G66/Knock Sensor 3 G198/Knock Sensor 4 G199 tightened to 20 Nm.

1. The Motronic Engine Control Module (ECM) J623 fuses 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 the engine cover with air filter --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

Note. Before disconnecting the Knock Sensor electrical harness connectors, mark the component location.

1. Disconnect the green Knock Sensor (KS) 1 G61 electrical harness connector - 1 - or the gray Knock Sensor (KS) 2 G66 electrical harness connector - 2 -.
2. or Knock Sensor 3 G198

Scheme 663

1. or Knock Sensor 4 G199

Checking internal resistance

Scheme 664

1. Using a Multimeter , check each Knock Sensors' terminals 1 to 2 for an internal short.

Specified value: infinity (Infinity).

If the specified value was not obtained

1. Replace the faulty Knock Sensor (KS) 1 G61/or Knock Sensor (KS) 2 G66/or Knock Sensor 3 G198/or Knock Sensor 4 G199 --> «15 - ENGINE - CYLINDER HEAD, VALVETRAIN»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If the specified value was obtained

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623)

Scheme 665

1. Using a Multimeter , Check the Knock Sensors' electrical harness connectors to the Motronic Engine Control Module (ECM) J623 electrical harness connector T121 for an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was not obtained

1. Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
2. Check the wiring connection for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring and the resistance was not OK

1. Replace the faulty Knock Sensor (KS) 1 G61/Knock Sensor (KS) 2 G66/or Knock Sensor 3 G198/or Knock Sensor 4 G199 --> «15 - ENGINE - CYLINDER HEAD, VALVETRAIN»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) .

If no malfunction is found in the wiring and the resistance was OK

1. Replace the Motronic Engine Control Module (ECM) J623.
2. Install the engine cover with air filter --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

Ignition Coils with Power Output Stage N70, N127, N291, N292, N323, N324, N325, N326 , checking

The following procedure is used to diagnose all Ignition Coils with Power Output Stage.

Special tools, testers and auxiliary items required

1. Multimeter.
2. Diode test lamp.
3. Wiring diagram.

Test requirements

1. The Ignition Coils with Power Output Stage N70, N127, N291, N292, N323, N324, N325, N326 fuses OK.
2. The Motronic Engine Control Module (ECM) Power Supply Relay J271 OK.
3. The Engine Speed (RPM) Sensor G28 OK, .
4. The Camshaft Position (CMP) Sensor G40 OK, --> «Camshaft Position (CMP) Sensor G40 and Camshaft Position (CMP) Sensor 2 G163 , checking»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__camshaft-position-cmp-sensor-g40-and) .

1. Battery voltage at least 12.5 volts.
2. All electrical consumers such as, lights and rear window defroster, switched off.
3. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
4. A/C switched off.

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

Procedure

1. Remove the engine cover with air filter --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

Scheme 666

1. Remove the Ignition Coils with Power Output Stage N70, N127, N291, N292, N323, N324, N325, N326 electrical harness screws - 1 -.
2. Disconnect the Ignition Coils with Power Output Stage N70, N127, N291, N292, N323, N324, N325, N326 electrical harness connectors from the Ignition Coils with Power Output Stage N70, N127, N291, N292, N323, N324, N325, N326.

Checking voltage supply

1. Switch the ignition on.

Scheme 667

1. Using a Multimeter , check the Ignition Coil electrical harness connector terminals 1 to 4 for voltage.

Specified value: battery voltage. Repeat for each ignition coil connector.

1. Switch the ignition off.

If the specified value was not obtained

1. Check the Ignition Coil electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) Power Supply Relay J271 terminal 87 for an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was not obtained

1. Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
2. Check the wiring connection for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If the specified values were obtained

Checking activation

1. Disable the power supply to the Fuel Injectors N70, N127, N291, N292, N323, N324, N325, N326 by removing Fuse 29 (on fuse panel B) from the fuse holder SB29, in the E-box, plenum chamber.

1. Using a diode test lamp , check the Ignition Coil electrical harness connector terminals 2 to 3 for voltage.
2. Operate the starter.

The LED should flicker.

1. Switch the ignition off.

If the LED flickers and the voltage was OK

1. Replace the faulty Ignition Coils with Power Output Stage N70, N127, N291, N292, N323, N324,N324,N325,N326 --> «28 IGNITION/GLOW PLUG SYSTEM»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the LED does not flicker

Checking wiring

If the manufacturers test box is being used. Perform the following step.

1. Install the test box. Refer to --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

If the manufacturers test box is not being used. Perform the following step.

1. Remove the Motronic Engine Control Module (ECM) J623. Refer to --> «Motronic Engine Control Module (ECM) J623 , replacing»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__motronic-engine-control-module-ecm-j623) .

1. Using a Multimeter , Check the Ignition Coil electrical harness connector to the Motronic Engine Control Module (ECM) J623 electrical harness connector T60 for an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was not obtained

1. Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
2. Check the wiring connection for damage, corrosion, lose or broken terminals.
3. If necessary, repair the faulty wiring connection.

If the specified values were obtained

1. Replace Motronic Engine Control Module (ECM) J623.

Scheme 668

1. Connect the Ignition Coils with Power Output Stage N70, N127, N291, N292, N323, N324, N325, N326 electrical harness connectors - arrows - to the Ignition Coils with Power Output Stage N70, N127, N291, N292, N323, N324, NM325, N326.

1. Install the Ignition Coils with Power Output Stage N70, N127, N291, N292, N323, N324, N325, N326 electrical harness screws - 1 -.
2. Install the engine cover with air filter --> «24 MULTIPORT FUEL INJECTION (MFI)»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bhf) .

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. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

1. End of diagnosis.

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. All manufacturers special tools as well as common tools may contain a manufacturer specific part number. These tools may be substituted with an equivalent aftermarket tool or are available for purchase through Audi. . Manufacturers special tools as well as common tools that contain a manufacturer specific part number may be referenced in the test procedure illustrations showing the tool use or installation. If the manufacturer specific tool is not being used, an equivalent aftermarket tool may be installed in the same manner as the manufacturers special tool. The manufacturers test box Test Box 105 Pin VAG1598/42 is available for purchase or rental. . 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 hoist, before working on the electrical components! Do not make direct contact on electrical harness connector terminals! If special testing equipment is required during road test, note the following

Safety precautions

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 669

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/s4/b7-2004-2008/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 the DTC memory of the Transmission Control Module (TCM) J217. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

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/s4/b7-2004-2008/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 the DTC memory of the Transmission Control Module (TCM) J217. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

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/s4/b7-2004-2008/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 the DTC memory of the Transmission Control Module (TCM) J217. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

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/s4/b7-2004-2008/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 the DTC memory of the Transmission Control Module (TCM) J217. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

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/s4/b7-2004-2008/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 the DTC memory of the Transmission Control Module (TCM) J217. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

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/s4/b7-2004-2008/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 the DTC memory of the Transmission Control Module (TCM) J217. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

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.

Work procedure

Check the control module identification of the previous Transmission Control Module (TCM) J217 as follows

1. Connect the scan tool.
2. Switch the ignition to the "ON" position.
3. 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/s4/b7-2004-2008/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/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-09-vehicle-information) .
2. Generate readiness code. --> «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

Transmission Control Module (TCM) J217 voltage supply, 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. --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.
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/s4/b7-2004-2008/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 the DTC memory of the Transmission Control Module (TCM) J217. Refer to «Diagnostic Mode 04: Reset/delete diagnostic data»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__diagnostic-mode-04-resetdelete-diagnostic-data) .
3. If the DTC memory was erased, generate readiness code. Refer to «Readiness Code Description»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-generic-scan-tool-engine-codes-bhf__readiness-code-description) .

Continuously Variable Transmission (CVT) 01V, checking

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

1. 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS for 5 SPD. AUTOMATIC TRANSMISSION 01V
2. 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - 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. For a further description of the monitor strategies, a document reference has been provided throughout this Generic Scan Tool (GST) manual and can be easily identified as. e.g. Bosch Motronic ME 7 OBD System Strategy.

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 2007 S4 4.2L 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 scan tool 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 scan tool.
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 scan tool 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 scan tool 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 scan tool.
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 scan tool 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 scan tool 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 scan tool.
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 scan tool screen.

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

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

1. SAE P0xxxDTCs..
2. SAE P1xxx-DTCs.
3. SAE P2xxxDTCs..
4. SAE P3xxxDTCs..

1. SAE U0xxxDTCs

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 scan tool and protocol used, diagnostic mode 04 and the information provided may be referred to by a different name.

Procedure

1. Connect the scan tool.
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 scan tool will display: "Diagnostic data are being erased".

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

Diagnostic Mode 05: Check lambda test results

Mode 05 allows access to the Oxygen Sensor test results. Mode 05 is divided into test identifiers (TIDS).

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

Test-ID 01 ($01): Oxygen Sensor in front of Catalytic Converter Bank 1 - Sensor 1.

1. Connect the scan tool.
2. Start the engine and let run at idle speed.
3. Select "Mode 5".

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

1. Select the desired "Test-ID".
2. Check specified values at idle.

1. If any component or system fails to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure.
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 02 ($02): Oxygen Sensor Behind Catalytic Converter Bank 1- Sensor 2

1. Connect the scan tool.
2. Start the engine and let run at idle speed.
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".
2. Check specified values at idle.

1. If any component or system fails to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure.
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 05 ($05): Oxygen Sensor in front of Catalytic Converter Bank 2 - Sensor 1

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

Select "Test-ID 05 ($05)".

1. Select the desired "Test-ID".
2. Check specified values at idle.

1. If any component or system fails to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure.
2. Switch the ignition off.
3. End of diagnosis.

Test-ID 06 ($06): Oxygen Sensor Behind Catalytic Converter Bank 2 - Sensor 2.

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

Select "Test-ID 06 ($06)".

1. Select the desired "Test-ID".
2. Check specified values at idle.

1. If any component or system fails to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure.
2. Switch the ignition off.
3. End of diagnosis.

Diagnostic mode 6: 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 the scan tool and protocol used, the information displayed 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 catalytic converter and cylinder head.
2. No DTCs in the DTC memory.
3. Coolant temperature at least 80°C.

Work procedure

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

Select the desired "Test-ID".

The current minimum and maximum values will be displayed on the scan tool screen.

Mode 06 - $01 (01): Catalytic Conversion (Bank 1)

1. Connect the scan tool.
2. Start the engine and let run at idle speed.
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".
2. Check specified values at idle.

1. If any component or system fails to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure.
2. Switch the ignition off.

Mode 06 - TID $01 (01): Catalytic Conversion (Bank 2)

1. Connect the scan tool.
2. Start the engine and let run at idle speed.
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".
2. Check specified values at idle.

1. If any component or system fails to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure.
2. Switch the ignition off.

Mode 06 - TID $02 (02): Oxygen Sensor (Bank 1, Sensor 1)

1. Connect the scan tool.
2. Start the engine and let run at idle speed.
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".
2. Check specified values at idle.

1. If any component or system fails to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure.
2. Switch the ignition off.

Mode 06 - TID $02 (02): Oxygen Sensor (Bank 2, Sensor 1)

1. Connect the scan tool.
2. Start the engine and let run at idle speed.
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".
2. Check specified values at idle.

1. If any component or system fails to meet the specified values, refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTCs or the corresponding diagnostic repair procedure.
2. Switch the ignition off.
3. End of diagnosis.

Mode 06 - $03 (03): Secondary Air Injection (AIR) System (Bank 1)

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

Select "TID $03 (03)".

1. Select the desired "Test-ID".
2. Check specified values at idle.

Mode 06 - TID $03 (03): Secondary Air Injection (AIR) System (Bank 2)

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

Select "TID $03 (03)".

1. Select the desired "Test-ID".
2. Check specified values at idle.

Mode 06 - TID $05 (05): Tank Ventilation System, Tank Vent Valve

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

Select "TID $05 (05):".

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

Mode 06 -TID $05 (05): Tank Ventilation System, Tank Leak Test

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

Select "TID $05 (05):".

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.
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 scan tool 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 scan tool.
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 scan tool screen.

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

1. SAE P0xxxDTCs..
2. SAE P1xxx-DTCs.
3. SAE P2xxxDTCs..
4. SAE P3xxxDTCs..

1. SAE U0xxxDTCs

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 scan tool 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 scan tool.
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 scan tool 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 scan tool 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 scan tool.
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 scan tool 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 scan tool.
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 scan tool 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 scan tool and switch the ignition off.
3. End of operation.

Fuel, air mixture, and additional emissions regulations

Fuel and air ratios

Ignition system

Additional exhaust regulation

Speed and idle control

Control module and output signals

Transmission