2.0l - Multiport Fuel Injection (mfi) - Engine Code(s): Bpy (roadster) Audi TT 8J

MOTRONIC FUEL INJECTION SYSTEM, SERVICING

For all Motronic fuel injection system component locations. Refer to 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection & Ignition, Engine Code(s): BWA. Repair Group 24.

For all Motronic fuel injection system removal/installation procedures and torque specifications. Refer to 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection & Ignition, Engine Code(s): BWA. Repair Group 24.

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 VAG 1598/42 is available for purchase or rental.

SAFETY PRECAUTIONS

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

CLEAN WORKING CONDITIONS

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

TECHNICAL DATA

OXYGEN SENSOR (O2S) HEATER -Z19-, CHECKING

Note. Oxygen Sensor (O2S) Heater -Z19- is part of Heated Oxygen Sensor (HO2S) -G39- and cannot be replaced separately. When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S) -G39-, use only gold-plated terminals.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB6- OK.
2. Motronic Engine Control Module (ECM) Power Supply Relay -J271- OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
6. A/C switched off.
7. Ground (GND) connections between engine/transmission/chassis OK.
8. Ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Start diagnosis

Remove the engine cover with air filter.

Checking internal resistance

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

Scheme 368

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- terminals 3 to 4 for resistance.

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

If the specification was not obtained

Replace the Heated Oxygen Sensor (HO2S) -G39-.

If the specification was obtained

Checking voltage supply

Crank the engine (engine may run).

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminal 4 to Ground (GND) for voltage.

Scheme 369

Switch the ignition off.

Specified value: Battery voltage.

If the specification was not obtained

Check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminal 4 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 2/87 an open circuit, a short circuit to each other, Battery (+), or Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

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.

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminal 3 to the Engine Control Module (ECM) -J623- electrical harness connector T94 terminal 51 for resistance.

Specified value: 1.5 ohms max.

If the specification was not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

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

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

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

Replace the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

OXYGEN SENSOR (O2S) 1 (BEHIND THREE WAY CATALYTIC CONVERTER (TWC)) HEATER - Z29-, CHECKING

Note. Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater - Z29- is part of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and cannot be replaced separately. Vehicle must be raised before electrical harness connector for the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- is accessible. When servicing terminals in harness connector of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-, use only gold-plated terminals.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB6- OK.
2. Motronic Engine Control Module (ECM) Power Supply Relay -J271- OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
6. A/C switched off.
7. Ground (GND) connections between engine/transmission/chassis OK.
8. Ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to Engine Control Module (ECM) -J623-, REPLACING .

Start diagnosis

Remove the retaining nuts -1 and 2- and the cover.

Scheme 370

Checking internal resistance

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

Scheme 371

Using a multimeter, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- electrical harness connector terminals 1 to 2 for resistance.

Scheme 372

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

If the specification was not obtained

Replace the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130-.

If the specification was obtained

Checking voltage supply

Crank the engine (engine may run).

Using a multimeter, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130- electrical harness connector terminal 1 to Ground (GND) for voltage.

Scheme 373

Switch the ignition off.

Specified value: Battery voltage.

If the specification was not obtained

Check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130- electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 2/87 an open circuit, a short circuit to each other, Battery (+), or Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

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.

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a multimeter, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- electrical harness connector terminal 2 to the Engine Control Module (ECM) -J623- electrical harness connector T94 terminal 7 for resistance.

Specified value: 1.5 ohms max.

If the specification was not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

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

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

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

Replace the Engine Control Module (ECM) -J623-. Refer to Engine Control Module (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

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 and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SC11- 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".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. Coolant Temperature at least 80° C.
8. Ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to Engine Control Module (ECM) -J623-, REPLACING .

Start diagnosis

Connect the scan tool.

Start engine and let it run at idle.

Using the scan tool, Check the air flow quantity of the Mass Air Flow (MAF) Sensor -G70- at idle

End diagnosis and switch ignition off.

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

Check voltage supply of Mass Air Flow (MAF) Sensor -G70- CHECKING VOLTAGE SUPPLY .

If specified value was not obtained

Check the Mass Air Flow (MAF) Sensor -G70- electrical circuit CHECKING ELECTRICAL CIRCUIT .

Checking Voltage Supply

Disconnect the Mass Air Flow (MAF) Sensor -G70- electrical harness connector -3-.

Scheme 374

Start the engine and let it run at idle.

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

Scheme 375

Specified value: battery voltage.

Switch the ignition off.

If specified value was not obtained

Check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminal 3 to the Power Supply Relay (terminal 50) -J682- terminal 2/30 for an open circuit, a short circuit to each other, Battery (+), and Ground (GND).

Specified value: 1.5 ohms max.

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

Checking electrical circuit

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a multimeter, check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T94 terminals for resistance.

Specified value: 1.5 ohms max.

If the specification is not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

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

Replace Mass Air Flow (MAF) Sensor -G70-.

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

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

Replace the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

THROTTLE VALVE CONTROL MODULE -J338-, CHECKING

Note. Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow (MAF) Sensor -J338-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The 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".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. Throttle valve must not be damaged or dirty.
8. Coolant Temperature at least 80° C.

Function

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

The Throttle Valve Control Module -J338- is made up of the following components

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

The Throttle Valve Control Module -J338- cannot be serviced separately and must be serviced as a unit.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to Engine Control Module (ECM) -J623-, REPLACING .

Start diagnosis

Connect the scan tool.

Switch ignition on.

Using the scan tool, check the throttle valve position (absolute) at idle stop

Slowly depress the accelerator pedal to Wide Open Throttle (WOT) stop while observing the percentage display. The percentage display must increase uniformly.

Using the scan tool, check the throttle valve position (absolute) at Wide Open Throttle (WOT) stop

End diagnosis and switch ignition off.

If the specified values are not obtained

Remove the Throttle Valve Control Module -J338 - far enough so that the electrical connector terminals are reached.

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

Scheme 376

Checking resistance

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

Scheme 377

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

If the specification was not obtained

Replace the Throttle Valve Control Module - J338-.

If the specification was obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to Engine Control Module (ECM) -J623-, REPLACING .

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 Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for resistance.

Scheme 378

Specified value: 1.5 ohms max.

If the specification is not obtained

Check the wiring for an open circuit, a short circuit to each other, Battery (+), and Ground (GND).

If necessary, repair the faulty wiring connection.

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

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

Replace Throttle Valve Control Module -J338-.

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

If the DTC does return and no malfunction is detected in the wiring and the voltage supply was not OK

Replace the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

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 and workshop equipment required

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

Test requirements

1. The 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".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. Ignition switched off.
8. Engine cold.

Function test

Connect the scan tool.

Switch the ignition on.

Using the scan tool, check the coolant temperature

If the specified value is not obtained

Continue test according to the following table

If the specified value was obtained

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.

Replace the Engine Coolant Temperature (ECT) Sensor - G62-.

Checking internal resistance

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

Scheme 379

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

Scheme 380

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

Scheme 381

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

Replace the Engine Coolant Temperature (ECT) Sensor - G62-.

Testing If Display Is Approx. - 40.0° C

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

Using a jumper wire, connect the Engine Coolant Temperature (ECT) Sensor -G62- electrical harness connector terminals 1 to 2.

Check the value indicated on the scan tool display.

Scheme 382

If the value jumps to approx. 140.0° C

End diagnosis and switch the ignition off.

Replace the Engine Coolant Temperature (ECT) Sensor - G62-.

If indication remains at approx. -40.0° C

Testing If Display Approx. 140.0° C

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

If indication jumps to approx. -40.0° C

End diagnosis and switch ignition off.

Replace the Engine Coolant Temperature (ECT) Sensor - G62-.

If indication remains at approx. 140.0° C

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a Multimeter --, check the Engine Coolant Temperature (ECT) Sensor - G62- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

If the DTC does return and no malfunction is detected in the wiring and the voltage supply was not OK

Replace the Engine Control Module (ECM) -J623-. Refer to Engine Control Module (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

INTAKE AIR TEMPERATURE (IAT) SENSOR -G42-, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.
3. Cool spray (commercially available).

Test requirements

1. The 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".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. Ignition switched off.

Function test

Connect the scan tool.

Switch the ignition on.

Using the scan tool, check the intake air temperature

If the specified value is not obtained

Continue the test according to the following table

If the specified values are obtained

Remove the Intake Air Temperature (IAT) Sensor -G42-.

Spray the Intake Air Temperature (IAT) Sensor -G42- with a commercially available cool spray while observing the temperature value on the scan tool.

The temperature value must decrease.

End diagnosis and switch the ignition off.

If the intake air temperature does not decrease

Replace the Intake Air Temperature (IAT) Sensor -G42-.

If the intake air temperature does decrease

Checking internal resistance

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

Scheme 383

Using a multimeter, check the Intake Air Temperature (IAT) Sensor -G42- 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.

Specified values

Read-out examples

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 are not obtained

Replace the Intake Air Temperature (IAT) Sensor -G42-.

Testing If Display Approx. -40&Deg; C Or Approx. -46&Deg; C

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

Using a jumper wire, connect the Intake Air Temperature (IAT) Sensor -G42- electrical harness connector terminals 1 to 2.

Check the value indicated on the scan tool display.

If indication jumps to approx. 140° C

End diagnosis and switch ignition off.

Replace the Intake Air Temperature (IAT) Sensor -G42-.

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

Testing If Display Approx. 140&Deg; C

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

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

End diagnosis and switch ignition off.

Replace the Intake Air Temperature (IAT) Sensor -G42 -.

If the indication remains at approx. 140° C

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a Multimeter --, check the Intake Air Temperature (IAT) Sensor -G42 - electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

If necessary, repair the faulty wiring connection.

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If no malfunction is detected in the wiring

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

If the DTC does return and no malfunction is detected in the wiring and the voltage supply was not OK

Replace the Engine Control Module (ECM) -J623-. Refer to Engine Control Module (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

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 and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The 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".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. 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

Connect the scan tool.

Switch the ignition on.

Using the scan tool, check the engine speed

End diagnosis and switch ignition off.

If the specified value was not obtained

Checking internal resistance

Disconnect the Engine Speed (RPM) Sensor -G28- electrical harness connector -5-.

Scheme 384

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

Scheme 385

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

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

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

Replace the Engine Speed (RPM) Sensor -G28-.

If the specified values are obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a Multimeter --, check the Engine Speed (RPM) Sensor -G28- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Remove the Engine Speed (RPM) Sensor -G28- and check the sensor wheel for proper seating, damage and run-out.

If the sensor wheel is OK

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

If the DTC does return and no malfunction is detected in the wiring and the voltage supply was not OK

Replace the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

FUEL INJECTOR --, CHECKING

The following test procedure is used to diagnose Fuel Injectors -N30, N31, N32, N33-.

Special tools and workshop equipment required

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

Test requirements

1. The Engine Control Module (ECM) -J623- fuses OK.
2. The Engine Speed (RPM) Sensor -G28- OK, checking «ENGINE SPEED (RPM) SENSOR -G28-, CHECKING»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-multiport-fuel-injection-mfi-engine-codes-bpy-roadster__engine-speed-rpm-sensor-g28-checking) .
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
6. A/C switched off.
7. Ground (GND) connections between engine/transmission/chassis OK.
8. Ignition switched off.

Observe safety precautions.

Observe rules for cleanliness.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Start diagnosis

Remove the engine cover with air filter.

Disconnect the Fuel Injector -- electrical harness connectors from Fuel Injectors --.

Checking internal resistance

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

Scheme 386

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

If the specified value was not obtained

Replace the malfunctioning Fuel Injector --.

If the specified value was obtained

Checking activation

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

Scheme 387

Operate the starter and test the activation of the Fuel Injector --.

LED should flicker.

Switch the ignition off.

If LED does not flicker

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a Multimeter --, check the Fuel Injector -- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for resistance.

Scheme 388

Specified value: 1.5 ohms Max.

If the specification is not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

If the DTC does return and no malfunction is detected in the wiring and the voltage supply was not OK

Replace the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

INTAKE FLAP MOTOR -V157- /INTAKE MANIFOLD RUNNER POSITION SENSOR -G336-, CHECKING

Note. Use only gold-plated terminals when servicing terminals in the electrical harness connector of the Intake Flap Motor -V157- /Intake Manifold Runner Position Sensor -G336-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The 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".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. Ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Start diagnosis

Remove the engine cover with air filter.

Disconnect the Intake Flap Motor -V157- /Intake Manifold Runner Position Sensor -G336- electrical harness connector -arrow-.

Scheme 389

Switch the ignition on.

Using a multimeter, check the Intake Flap Motor -V157- /Intake Manifold Runner Position Sensor -G336- electrical harness connector terminals 1 to 3 for voltage.

Specified value: about 5 V

Switch ignition off.

If the specified value was obtained

Replace the Intake Flap Motor - V157- /Intake Manifold Runner Position Sensor - G336-.

If the specified value was not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a Multimeter --, check the Intake Flap Motor - V157- /Intake Manifold Runner Position Sensor - G336- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

If the DTC does return and no malfunction is detected in the wiring and the voltage supply was not OK

Replace the Engine Control Module (ECM) -J623-. Refer to Engine Control Module (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

FUEL PRESSURE SENSOR -G247-, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Engine Control Module (ECM) - J623- fuses OK.
2. The fuel filter OK.
3. The battery voltage at least 12.5 V.
4. All electrical consumers switched off (radiator fan must NOT run during test).
5. A/C switched off.
6. The fuel tank at least 1 / 4 filled.
7. The ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Start diagnosis

Remove the engine cover with air filter.

Checking voltage

Disconnect the Fuel Pressure Sensor -G247- electrical harness connector.

Switch the ignition on.

Using a Multimeter --, check the Fuel Pressure Sensor -G247- electrical harness connector terminals for voltage.

Switch the ignition off.

If the specified value was obtained

Replace the Fuel Pressure Sensor -G247-.

If the specified value was not obtained

Checking wiring connections

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a Multimeter --, check the Fuel Pressure Sensor -G247- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification is not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

If the DTC does return and no malfunction is detected in the wiring and the voltage supply was not OK

Replace the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

LOW FUEL PRESSURE SENSOR -G410-, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Fuel Pump (FP) Control Module -J538- OK.
2. The Engine Control Module (ECM) - J623- fuses OK.
3. The fuel filter OK.
4. The battery voltage at least 12.5 V.
5. All electrical consumers switched off (radiator fan must NOT run during test).
6. A/C switched off.
7. The fuel tank at least 1 / 4 filled.
8. The ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Start diagnosis

Remove the engine cover with air filter.

Checking voltage

Disconnect the Low Fuel Pressure Sensor -G410- electrical harness connector -2-.

Scheme 390

Switch the ignition on.

Using a multimeter --, check the Low Fuel Pressure Sensor -G410- electrical harness connector for voltage.

Switch the ignition off.

If the specified value was obtained

Replace the Low Fuel Pressure Sensor -G410-.

If the specified value was not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a Multimeter --, check the Low Fuel Pressure Sensor -G410- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open circuit according to the wiring diagram.

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

If the DTC does return and no malfunction is detected in the wiring and the voltage supply was not OK

Replace the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

FUEL PRESSURE REGULATOR VALVE -N276-, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Engine Control Module (ECM) - J623- fuses OK.
2. The fuel filter OK.
3. The battery voltage at least 12.5 V.
4. All electrical consumers switched off (radiator fan must NOT run during test).
5. A/C switched off.
6. The fuel tank at least 1 / 4 filled.
7. The ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Start diagnosis

Remove the engine cover with air filter.

Checking resistance

Disconnect the Fuel Pressure Regulator Valve -N276- electrical harness connector -2-.

Using a multimeter --, check the Fuel Pressure Regulator Valve -N276- terminals 1 to 2 for resistance.

Scheme 391

Specified value: 25 to 35 ohms (at approx. 20° C)

If the specified value was not obtained

Replace the Fuel Pressure Regulator Valve -N276-.

If the specified value was obtained

Checking voltage

Switch the ignition on.

Using a multimeter --, check the Fuel Pressure Regulator Valve -N276- electrical connector terminal 1 to Ground (GND) for voltage.

Specified value: battery voltage.

Switch the ignition off.

If the specified value was not obtained

Check the wiring from the Fuel Pressure Regulator Valve -N276- electrical connector terminal 1 to the Engine Component Power Supply Relay -J757- socket 2/87 for a short circuit to Battery positive (+), Ground (GND), or an open circuit.

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a multimeter --, check the Fuel Pressure Regulator Valve -N276- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

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

Replace the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

HEATED OXYGEN SENSOR (HO2S) -G39- AND OXYGEN SENSOR REGULATION BEFORE CATALYTIC CONVERTER, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB6- OK.
2. Motronic Engine Control Module (ECM) Power Supply Relay -J271- OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
6. A/C switched off.
7. Ground (GND) connections between engine/transmission/chassis OK.
8. Ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Start diagnosis

Perform the function test in Diagnostic Mode 06. Refer to DIAGNOSTIC MODE 06 - READ TEST RESULTS FOR SPECIFIC DIAGNOSTIC FUNCTIONS .

If specified values are obtained

End diagnosis and switch the ignition off.

If the specified values are not obtained

Remove the engine cover with air filter.

Checking primary voltage

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

Start the engine.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminals 1 to 5 for voltage.

Specified value: 0.400 to 0.500 Volts

Switch the ignition off.

If the specified value was obtained

Replace the Heated Oxygen Sensor (HO2S) -G39-.

If the specified value was not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a Multimeter --, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T94 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

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

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

If the DTC does return and no malfunction is detected in the wiring and the voltage supply was not OK

Replace the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

OXYGEN SENSOR (O2S) BEHIND THREE WAY CATALYTIC CONVERTER (TWC) -G130-, CHECKING

Note. Vehicle must be raised before the electrical connector for the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- is accessible. Use only gold-plated terminals when servicing terminals in the electrical harness connector of the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB6- OK.
2. Motronic Engine Control Module (ECM) Power Supply Relay -J271- OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
6. A/C switched off.
7. Ground (GND) connections between engine/transmission/chassis OK.
8. Ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Start diagnosis

Perform the function test in Diagnostic Mode 06. Refer to DIAGNOSTIC MODE 06 - READ TEST RESULTS FOR SPECIFIC DIAGNOSTIC FUNCTIONS .

If specified values are obtained

End diagnosis and switch the ignition off.

If the specified values are not obtained

Remove the retaining nuts -1 and 2- and cover.

Checking primary voltage

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

Switch the ignition on.

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

Scheme 392

Specified value: 0.400 to 0.500 Volts

Switch the ignition off.

If the specified value was obtained

Replace the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130-.

If the specified value was not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Using a Multimeter --, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T94 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

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

Erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If the DTC does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

If the DTC does return and no malfunction is detected in the wiring and the voltage supply was not OK

Replace the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End of diagnosis

FUNCTION

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, fuel injectors and On Board Diagnostic (OBD).

ENGINE CONTROL MODULE (ECM) -J623- VOLTAGE SUPPLY, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. wiring diagrams.

Test requirements

1. Fuse -SA4- OK.
2. Fuse -SB9- OK.
3. Fuse -SC1- OK.
4. Fuse -SC31- OK.
5. Fuse -SC36- OK.
6. Motronic Engine Control Module (ECM) Power Supply Relay -J271- OK.
7. Power Supply Relay (terminal 50) -J682- OK.
8. The Ground (GND) connections at the engine and transmission OK.
9. The battery voltage at least 12.5 V.
10. The generator OK.

Start diagnosis

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

Install the test box. Refer to 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection & Ignition, Engine Code(s): BWA. Repair Group 24.

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

Remove the Engine Control Module (ECM) -J623-. Refer to Engine Control Module (ECM) -J623-, REPLACING .

Checking voltage supply

Using a Multimeter, check the following wiring connection for voltage.

Specified value: 12.5 V

If the specified value was not obtained

Using a Multimeter --, check the Engine Control Module (ECM) -J623- electrical harness connector terminal to the Battery -A- (+) for an open circuit or short to Ground (GND).

Check the electrical harness connectors for damage, corrosion, loose or broken terminals.

If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

Checking switched voltage supply

Switch the ignition on.

Using a Multimeter --, check the following wiring connection for voltage.

Specified value: 12.5. battery voltage.

Switch the ignition off.

If the specified value was not obtained

Using a Multimeter --, check the Engine Control Module (ECM) -J623- electrical harness connector terminal T94/87 to the Power Supply Relay (terminal 50) -J682- socket 2/30 for an open circuit.

Specified value: 1.5 ohms.

If the specified value was not obtained

Check the Engine Control Module (ECM) -J623- electrical harness connector terminal T94/87 to the Power Supply Relay (terminal 50) -J682- socket 2/30 for an open circuit or a short to Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

Using a Multimeter, check the following wiring connection for voltage.

Specified value: 12.5 V

If the specified value was not obtained

Using a Multimeter --, check the Engine Control Module (ECM) -J623- electrical harness connector terminal to the Battery -A- (+) for an open circuit or short to Ground (GND).

Check the electrical harness connectors for damage, corrosion, loose or broken terminals.

If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

Switch the ignition on.

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

Specified value: 12.5. battery voltage.

Switch the ignition off.

If the specified value was not obtained

Using a Multimeter --, check the Engine Control Module (ECM) -J623- electrical harness connector terminals T94/3, T94/5, T94/6 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 2/87 for an open circuit.

Specified value: 1.5 ohms.

If the specified value was not obtained

Check the Engine Control Module (ECM) -J623- electrical harness connector terminals T94/3, T94/5, T94/6 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 2/87 for an open circuit or a short to Ground (GND).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

Checking Ground (GND)

Using a Multimeter --, check the following wiring connections for an open circuit.

Specified value: 1.5 ohms.

If any of the specified values are not obtained

Check the Engine Control Module (ECM) -J623- electrical harness connector terminals to the following Ground (GND) locations for an open circuit or a short to Battery (+).

Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If necessary, repair the wiring connection.

If no malfunctions are found in the wiring and the voltage supply was OK

Perform a road test to verify any electrical repairs.

If the fault does not return

Repair complete, Generate readiness code. Refer to READINESS CODE .

End diagnosis.

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

Replace the Engine Control Module (ECM) -J623-. Refer to Engine Control Module (ECM) -J623-, REPLACING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

End diagnosis.

ENGINE CONTROL MODULE (ECM) -J623-, REPLACING

Removing

Special tools and workshop equipment required

1. Heat gun.

Note. When the 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 Engine Control Module (ECM) -J623- as follows

Connect the scan tool.

Switch the ignition on.

Using the scan tool, select "Vehicle information".

Select " Calibration Identification" in vehicle information.

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

Record the electronic control module identification number.

End diagnosis and switch the ignition off.

Procedure

Switch the ignition on.

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).

Remove the wiper arms caps.

Loosen the wiper arm nuts -arrows- several turns.

Scheme 393

Loosen the wiper arms from the wiper axle by rocking slightly.

Note. Do not force wiper arms off. If the wiper arms cannot be removed, use a standard puller.

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

Remove the rubber seal -1- and the plenum chamber cover -2-.

Scheme 394

Open the retaining clips -arrows- and remove the Engine Control Module (ECM) -J623-.

Scheme 395

The Engine Control Module (ECM) -J623- -1- is secured by a protective housing -2 and 5- and shear bolts -3 and 4

Scheme 396

Note. The threads of the shear bolts -3 and 4- have been coated with a locking compound and must be heated to be removed. The shear bolts -3- installed in the Engine Control Module (ECM) -J623- do not require heating. Only heat the shear bolts -4- that are not installed in the Engine Control Module (ECM) -J623-.

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

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

Scheme 397

Repeat the previous steps for the second shear bolt.

Remove the protective housing -2 and 5- from the Engine Control Module (ECM) -J623- -1-.

Remove the electrical harness connectors from the Engine Control Module (ECM) -J623- -1-.

Engine Control Module (ECM) -J623- installation

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

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

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

Engine Control Module (ECM) -J623- reprogramming

The new Engine Control Module (ECM) -J623- and immobilizer must be activated.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-03-read-dtc) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster__diagnostic-mode-04-erase-dtc) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-generic-scan-tool-engine-codes-bpy-roadster) .

See also:
• DIAGNOSTIC MODE 04 - ERASE DTC MEMORY
• READINESS CODE
• DIAGNOSTIC MODE 03 - READ DTC MEMORY
• DIAGNOSTIC MODE 06 - READ TEST RESULTS FOR SPECIFIC DIAGNOSTIC FUNCTIONS
• ENGINE CONTROL MODULE (ECM) -J623-, REPLACING
• CHECKING VOLTAGE SUPPLY
• CHECKING ELECTRICAL CIRCUIT
• TESTING IF DISPLAY IS APPROX. - 40.0° C
• TESTING IF DISPLAY APPROX. 140.0° C
• TESTING IF DISPLAY APPROX. -40° C OR APPROX. -46° C
• TESTING IF DISPLAY APPROX. 140° C
• ENGINE SPEED (RPM) SENSOR -G28-, CHECKING