GENERAL NOTES ON IGNITION SYSTEM
For all Ignition/Glow plug system component locations. Refer to 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection & Ignition, Engine Code(s): IGNITION/GLOW PLUG SYSTEM .
For all Ignition/Glow plug system removal/installation procedures and torque specifications. Refer to 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection & Ignition, Engine Code(s): IGNITION/GLOW PLUG SYSTEM .
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
| WARNING | Observe the following for all installations, especially in the engine compartment due to lack of room: Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed. Watch for sufficient clearance to all moving or hot components. Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. Test equipment must always be secured to the rear seat and operated by a second person. Test and measuring equipment that is operated from the passenger seat, the person seated could be injured in the event of an accident involving deployment of the passenger-side airbag. Do not touch or disconnect ignition wires when engine is running or turning at starting RPM. Only disconnect and reconnect wires for injection and ignition system, including test leads, if the ignition is turned off. |
| WARNING | The use of nails, paper clips, or another unauthorized materials to back-probe electrical harness connectors is strictly prohibited and may cause damage to the electrical harness connectors, terminal ends or damage to a component. Use only the manufacturers test lead kit or an equivalent aftermarket test lead kit for back-probing all electrical harness connectors. |
TEST DATA, SPARK PLUGS
| Engine code | BWA (2.0L / 147 kW Turbo-FSI engine) | |
|---|---|---|
| Engine Control Module (ECM) System identification | Motronic ME 9.1 | |
| Engine idle speed | 640 to 800 RPM (not adjustable) | |
| Engine speed (RPM) limitation | Starting at approx. 6500 RPM | |
| Ignition sequence | 1-3-4-2 | |
| Ignition timing | Not adjustable, regulated by Electronic control module | |
| Ignition system | Single coil ignition system with 4 ignition coils (output stages integrated) that are connected directly to spark plugs by the ignition cables. | |
| Spark plug tightening torque | 30 Nm | |
CAMSHAFT POSITION (CMP) SENSOR -G40-, CHECKING
Note. Use only gold-plated terminals when servicing terminals in harness connector of Camshaft Position (CMP) Sensor -G40-.
Special tools and workshop equipment required
- Multimeter.
- Wiring diagram.
Test requirements
- The Engine Control Module (ECM) - J623- fuses OK.
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
- 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. Refer to 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection & Ignition, Engine Code(s): BWA. Repair Group 24.
Disconnect the Camshaft Position (CMP) Sensor -G40- electrical harness connector -1-.
Scheme 38
Switch the ignition on.
Using a Multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector terminals 1 to 3 for voltage.
Scheme 39
Specified value: about 5.0 V
Switch the ignition off.
If the specification was not obtained
Checking wiring
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 .
Using a Multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector to the Engine Control Module (ECM) electrical harness connector T60 for resistance.
Scheme 40
| Camshaft Position (CMP) Sensor -G40- electrical harness connector terminals | Engine Control Module (ECM) electrical harness connector T60 terminals or test box sockets |
|---|---|
| 1 | 26 |
| 2 | 44 |
| 3 | 14 |
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
If necessary, repair the faulty wiring connection.
If no malfunction is found in the wiring and voltage supply was OK
Replace the Camshaft Position (CMP) Sensor -G40-. Refer to 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection & Ignition, Engine Code(s): BWA. Repair Group 24..
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
- 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) .
- 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) .
- 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
CAMSHAFT ADJUSTMENT VALVE 1 -N205-, CHECKING
Special tools and workshop equipment required
- Multimeter.
- Wiring diagram.
Test requirements
- Fuse -SB7- fuse OK.
- Motronic Engine Control Module (ECM) Power Supply Relay -J271- OK.
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
- 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. Refer to 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection & Ignition, Engine Code(s): BWA. Repair Group 24.
Disconnect Camshaft Adjustment Valve 1 -N205- electrical harness connector -1-.
Scheme 41
Using a Multimeter, check the Camshaft Adjustment Valve 1 -N205- for resistance.
Scheme 42
Specified value: 5.0 to 8.0 ohms (at approx. 20° C)
If the specified value was not obtained
Replace the Camshaft Adjustment Valve 1 -N205-. Refer to 2.0 Liter 4-Cyl. 4V Turbo Engine Mechanical, Engine Code(s): BWA. Repair Group 15.
If the specified value was obtained
Checking voltage
Switch the ignition on.
Using a Multimeter, Check the Camshaft Adjustment Valve 1 -N205- electrical harness connector terminal 1 to Ground (GND) for voltage.
Switch the ignition off.
Specified value: battery voltage.
If the specified value was not obtained
Check the Camshaft Adjustment Valve 1 -N205- electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 2/87 for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
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.
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 .
Using a Multimeter, Check the Camshaft Adjustment Valve 1 -N205- electrical harness connector terminal 2 to the Engine Control Module (ECM) electrical harness connector T60 terminal 20 for resistance.
Scheme 43
| Camshaft Adjustment Valve 1 -N205- electrical harness connector terminal | Engine Control Module (ECM) electrical harness connector T60 terminal or test box socket |
|---|---|
| 2 | 20 |
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
If necessary, repair the faulty wiring connection.
If no malfunction is found in the wiring and 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
- 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) .
- 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) .
- 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
KNOCK SENSOR (KS) 1 -G61- /KNOCK SENSOR (KS) 2 -G66-, CHECKING
The following procedure is used to diagnose all Knock Sensors --.
Special tools and workshop equipment required
- Multimeter.
- Wiring diagram.
Test requirements
- The mounting bolt of Knock Sensor (KS) 1 -G61- /Knock Sensor (KS) 2 -G66- tightened to 20 Nm.
- The Engine Control Module (ECM) - J623- fuses OK.
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
- 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. Refer to 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection & Ignition, Engine Code(s): BWA. Repair Group 24.
Disconnect the Knock Sensor (KS) 1 -G61- electrical harness connector -1- or the Knock Sensor (KS) 2 -G66- electrical harness connector -2-.
Scheme 44
Checking internal resistance
Using aMultimeter, check the Knock Sensor -- terminals 1 to 2 for an internal short.
Scheme 45
Specified value: infinity (Infinity).
If the specified value was not obtained
Replace the faulty Knock Sensor (KS) 1 -G61- /Knock Sensor (KS) 2 -G66-. Refer to 2.0 Liter 4-Cyl. 4V Turbo Engine Mechanical, Engine Code(s): BWA. Repair Group 15.
If the specified value was obtained
Checking wiring
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 .
Using a Multimeter, Check the Knock Sensor -- electrical harness connector to the Engine Control Module (ECM)J623 electrical harness connector T60 for an open circuit.
Scheme 46
| Knock Sensor (KS) 1 -G61- electrical harness connector terminals | Engine Control Module (ECM) electrical harness connector T60 terminals or test box sockets |
|---|---|
| 1 | 39 |
| 2 | 54 |
| 3 | 52 |
| Knock Sensor (KS) 2 -G66- electrical harness connector terminals | Engine Control Module (ECM) electrical harness connector T60 terminals or test box sockets |
|---|---|
| 1 | 9 |
| 2 | 24 |
| 3 | 52 |
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
If necessary, repair the faulty wiring connection.
If no malfunction is found in the wiring and the resistance was not OK
Replace the faulty Knock Sensor (KS) 1 -G61- /Knock Sensor (KS) 2 -G66-. Refer to 2.0 Liter 4-Cyl. 4V Turbo Engine Mechanical, Engine Code(s): BWA. Repair Group 15.
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
- 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) .
- 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) .
- 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
IGNITION COILS WITH POWER OUTPUT STAGE -N70, N127, N291, N292-, CHECKING
The following procedure is used to diagnose all Ignition Coils with Power Output Stage --.
Special tools and workshop equipment required
- Multimeter.
- Diode test lamp.
- Wiring diagram.
Test requirements
- The Spark Plugs -- OK.
- Fuse -SB8- fuses OK.
- The Motronic Engine Control Module (ECM) Power Supply Relay -J271- OK.
- The Engine Speed (RPM) Sensor -G28- OK.
- The Camshaft Position (CMP) Sensor -G40- OK.
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
- 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. Refer to 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection & Ignition, Engine Code(s): BWA. Repair Group 24.
Remove the Ignition Coil -- electrical harness screws -1-.
Scheme 47
Disconnect theIgnition Coil -- electrical harness connectors -arrows- from the Ignition Coil --.
Scheme 48
Checking voltage supply
Switch the ignition on.
Using a Multimeter, check the Ignition Coil -- electrical harness connector terminals 1 to Ground (GND) for voltage.
Scheme 49
Specified value: battery voltage.
Switch the ignition off.
If the specified value was not obtained
Check the Ignition Coil -- electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271 - terminal 2/87 for resistance.
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the Ignition Coil -- electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271 - terminal 2/87 for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
If necessary, repair the faulty wiring connection.
If the specified values were obtained
Checking activation
| WARNING | Do not touch the Ignition Coils -- connecting parts or adapter cables during the following test. |
Using a diode test lamp, check the Ignition Coil -- electrical harness connector terminals 2 to 3 for voltage.
Operate the starter.
The LED should flicker.
Switch the ignition off.
If the LED flickers and the voltage was OK
Replace the faulty Ignition Coil --. Refer to 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection & Ignition, Engine Code(s): BWA. Repair Group 28.
If the LED does not flicker
Checking wiring
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 .
Using a Multimeter, Check the Ignition Coil -- electrical harness connector terminals to the Engine Control Module (ECM)J623 electrical harness connector T60 for resistance.
| Ignition Coil | Electrical harness connector terminal | Engine Control Module (ECM) electrical harness connector T60 terminal or test box socket |
|---|---|---|
| Ignition Coils with Power Output Stage -N70 | 3 | 58 |
| Ignition Coils with Power Output Stage -N127 | 3 | 41 |
| Ignition Coils with Power Output Stage -N291 | 3 | 43 |
| Ignition Coils with Power Output Stage -N292 | 3 | 56 |
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, loose or broken terminals.
If necessary, repair the faulty wiring connection.
If the specified values were obtained
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
- 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) .
- 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) .
- 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