2.0L - Generic Scan Tool - Engine Code(s): Cdma (Roadster): Other Audi TT 8J facelift

SAFETY PRECAUTIONS

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 of cleanliness

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place removed parts on a clean surface and cover. Use lint-free cloths.
3. Carefully cover over opened components or seal, if repairs are not performed immediately.
4. When the system is open, do not work with compressed air. Do not move vehicle unless absolutely necessary.
5. 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.).
6. Separated electrical connectors: Protect from dirt and moisture. Make sure connections are dry when reconnecting.

MALFUNCTION INDICATOR LAMP ILLUMINATION

If the engine control module (ECM) recognizes a malfunction that leads to increased emission values, it indicates them by illuminating the malfunction indicator lamp (MIL) which is located in the instrument cluster.

The ECM switches on the MIL after the ignition is switched on. Shortly after the engine is started, the MIL goes out if the ECM does not detect a malfunction that increases the emission values.

If the ECM recognizes a malfunction that leads to increased emissions during the operation of the engine, the ECM switches on the MIL and an entry is stored in the DTC memory of the ECM.

CONTROLLER AREA NETWORK DATA LINK

The engine control module (ECM) communicates with data bus capable control modules via a CAN Data Link.

The databus capable control modules are connected via data bus wires, which are twisted together (CAN high and CAN low), and exchange information with the ECM. Missing or implausible information on the databus is recognized and stored as a malfunction based on specific DTC criteria.

The malfunction indicator lamp (MIL) is illuminated as a result of a CAN message sent by the ECM. The MIL can be turned on, turned off, or blink, depending on the message received.

ELECTRONIC POWER CONTROL WARNING LAMP

The engine control module (ECM) monitors electronic power control (EPC) components when the ignition is switched on.

If a malfunction is recognized in the EPC system, the ECM switches on the EPC warning lamp, which is located in the instrument cluster, and an entry is stored in the DTC memory of the ECM.

FUEL SUPPLY SYSTEM

For all fuel supply system component locations, removal/installation procedures and torque specifications, refer to the service information.

EVAPORATIVE EMISSION SYSTEM

The evaporative emission system has been designed to minimize the release of hydrocarbons from the fuel system into the atmosphere. The evaporative system components all work together with the ECM to prevent fuel vapor from escaping and route it to the intake manifold to be burned during normal combustion.

The leak detection system checks the integrity of the evaporative emission system by pressurizing the system.

1. When leak detection is activated, a pump pressurizes the evaporative system.
2. During the leak diagnosis, the system is monitored for a specific time period. If the pressure does not drop a specific amount during the time period, the system is considered to be sealed.
3. If the pressure drops greater than a specified amount during a specific time period, the system is pressurized once more. The engine control module measures the time until the pressure drops again. The control module uses the measured value to determine the size of the leak.

Leak diagnosis is activated automatically shortly following every engine start. If a malfunction is determined, an entry is made to the DTC memory. The Malfunction Indicator Lamp in the instrument cluster is illuminated if the malfunction is recognized for two subsequent starts.

For all evaporative system component locations, hose routing, removal/installation procedures and torque specifications, refer to the service information.

ELECTRONIC ENGINE POWER CONTROL

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 engine control module (ECM) by the throttle position sensor / accelerator pedal position sensor 2 (variable resistances; stored in one housing) that are connected with the accelerator pedal.

The accelerator pedal position (driver's intention) is a main input unit for the ECM.

Operation of the throttle valve occurs via an electric motor, the throttle drive for in the throttle valve control module. This is true across the entire engine speed and engine load spectrum.

The throttle valve is operated by the EPC according to specifications of engine control module (ECM).

With engine off and ignition switched on, the ECM controls the throttle drive according to specifications of throttle position sensor / accelerator pedal position sensor 2. This means, if the accelerator pedal is pressed half way, the throttle drive opens the throttle valve to the same degree; i.e. throttle valve is then opened approximately half way.

With engine running under load, ECM can open or close the throttle valve independently of the throttle position sensor / accelerator pedal position sensor 2.

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

In addition, it results in a significant reduction in emissions and fuel 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.

FUEL INJECTION SYSTEM

For all fuel injection system component locations, removal/installation procedures and torque specifications, refer to the service information.

ENGINE CONTROL MODULE

The ECM regulates fuel injection, throttle valve control module, oxygen sensor regulation, ignition, knock control, evaporative emission purge valve, engine speed limitation through the fuel injectors or the power supply relay, as well as OBD functions. For locations, removal/installation procedures, refer to the service information.

EXHAUST SYSTEM COMPONENTS

For all exhaust system, emission control component locations, removal/installation procedures and torque specifications, refer to the service information.

SECONDARY AIR INJECTION SYSTEM

The secondary air injection system improves the secondary oxidation within the catalytic converter which are due to the rich mixture during the cold start phase where the exhaust emissions contain an increased level of unburned hydrocarbons, 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.

1. During a cold start, the secondary air injection system injects air behind the exhaust valves. 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 system is switched on (after a delay) during idle after every subsequent engine start (up to a maximum coolant temperature) and is checked through on board diagnostic functions.

For all secondary air injection system component locations, removal/installation procedures and torque specifications, refer to the service information.

IGNITION SYSTEM

For all ignition and glow plug system component locations, removal/installation procedures and torque specifications, refer to the service information.

AUTOMATIC TRANSMISSION

The transmission control module receives information from transmission related components and uses this information to control shifting and operation of the transmission.

For all automatic transmission component locations, removal/installation procedures and torque specifications, refer to the service information.

PRELIMINARY CHECK

Before performing any pin point test or component diagnosis, a preliminary check must be performed.

Connect the scan tool.

Switch the ignition on.

Using the scan tool, check for any stored or related DTC's.

If other DTC's are stored

Repair these DTC's first before performing the following procedure.

If no other DTC's are stored

Using the scan tool, erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to attempt to duplicate the customers complaint.

If the DTC returns

Perform the diagnostic procedure.

If the DTC does not return

The fault is intermittent or a sporadic condition may exist.

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

If necessary, repair the faulty wiring connection.

Perform a road test to verify the repair.

If the DTC returns

Perform the diagnostic procedure.

If the DTC does not return

The fault may have been the result of a loose electrical connection.

Generate readiness code. Refer to READINESS CODE .

READINESS CODE

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 manufacturer's instruction information 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 must be between 10° C and 35° C.
4. Battery voltage must be a minimum of 12.5 volts.
5. Fuel tank level 1/4 to 3/4 full.

Drive Cycle Procedure

Connect the scan tool.

Switch the ignition on and start the vehicle.

Idle the vehicle for 2-3 minutes. This executes the O2 heater, misfire, secondary air injection, fuel trim, and purge system monitors.

Drive the vehicle at 45-55 mph for a continuous 7-minute period - avoid stopping. This executes the evaporative, O2 sensor, fuel trim, and misfire monitors.

Accelerate the vehicle to an engine speed of 5000 RPM; lift off the throttle until the engine speed is around 1200 rpm. This executes the fuel cut off.

Accelerate the vehicle smoothly to 60-65 mph, cruise constantly for 5 min, this executes the catalyst; O2 sensor, misfire, fuel trim, and purge system monitors.

Decelerate and idle the vehicle again for 3 minutes. This executes the misfire, secondary air injection, fuel trim, and purge system monitors.

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.

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 evaporative 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 no greater than 4° C and repeat the drive cycle operation.

If the drive cycle operation fails again.

Check the DTC memory for stored DTCs.

Repair the vehicle if necessary.

Repeat the drive cycle operation until all engine monitors have successfully run through and passed.

Remove the scan tool and switch the ignition off.

MONITOR-ID 01 : OXYGEN SENSOR MONITOR BANK 1 - SENSOR 1

Connect the scan tool.

Start the engine and run at idle.

Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Monitor-ID 01 ".

Select the desired "Test-ID (TID)" or "Hex-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTC or the corresponding diagnostic repair procedure DIAGNOSTIC MODE 03 - READ DTC MEMORY .

Switch the ignition off.

MONITOR-ID 02 : OXYGEN SENSOR MONITOR BANK 1- SENSOR 2

Connect the scan tool.

Start the engine and run at idle.

Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Monitor-ID 02".

Select the desired "Test-ID (TID)" or "Hex-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTC or the corresponding diagnostic repair procedure DIAGNOSTIC MODE 03 - READ DTC MEMORY .

Switch the ignition off.

Monitor-ID 21: Catalytic Converter Monitoring

Connect the scan tool.

Start the engine and run at idle.

Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Monitor-ID 21".

Select the desired "Test-ID (TID)" or "Hex-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTC or the corresponding diagnostic repair procedure DIAGNOSTIC MODE 03 - READ DTC MEMORY .

MONITOR-ID 61 : TANK VENT VALVE - FUNCTION CHECK

Connect the scan tool.

Start the engine and run at idle.

Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Monitor-ID 61".

Select the desired "Test-ID (TID)" or "Hex-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTC or the corresponding diagnostic repair procedure DIAGNOSTIC MODE 03 - READ DTC MEMORY .

Switch the ignition off.

MONITOR-ID 65 : OXYGEN SENSOR HEATER MONITOR BANK 1 - SENSOR 1

Connect the scan tool.

Start the engine and run at idle.

Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Monitor-ID 65".

Select the desired "Test-ID (TID)" or "Hex-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTC or the corresponding diagnostic repair procedure DIAGNOSTIC MODE 03 - READ DTC MEMORY .

Switch the ignition off.

MONITOR-ID 66 ($42): OXYGEN SENSOR HEATER MONITOR BANK 1 - SENSOR 2

Connect the scan tool.

Start the engine and run at idle.

Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Monitor-ID 66".

Select the desired "Test-ID (TID)" or "Hex-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTC or the corresponding diagnostic repair procedure DIAGNOSTIC MODE 03 - READ DTC MEMORY .

Switch the ignition off.

MONITOR-ID A2 : MIS-FIRE CYLINDER 1 DATA

Connect the scan tool.

Start the engine and run at idle.

Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Monitor-ID A2".

Select the desired "Test-ID (TID)" or "Hex-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTC or the corresponding diagnostic repair procedure DIAGNOSTIC MODE 03 - READ DTC MEMORY .

Switch the ignition off.

MONITOR-ID A3: MIS-FIRE CYLINDER 2 DATA

Connect the scan tool.

Start the engine and run at idle.

Select "Mode 6 Check test the results of components that are not continuously monitored".

Select "Monitor-ID A3:".

Select the desired "Test-ID (TID)" or "Hex-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTC or the corresponding diagnostic repair procedure DIAGNOSTIC MODE 03 - READ DTC MEMORY .

Switch the ignition off.

MONITOR-ID A4: MIS-FIRE CYLINDER 3 DATA

Connect the scan tool.

Start the engine and run at idle.

Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Monitor-ID A4".

Select the desired "Test-ID (TID)" or "Hex-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTC or the corresponding diagnostic repair procedure DIAGNOSTIC MODE 03 - READ DTC MEMORY .

Switch the ignition off.

MONITOR-ID A5 : MIS-FIRE CYLINDER 4 DATA

Connect the scan tool.

Start the engine and run at idle.

Select "Mode 6: Check test the results of components that are not continuously monitored".

Select "Monitor-ID A5".

Select the desired "Test-ID (TID)" or "Hex-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to Diagnostic "Mode 03: Interrogating Fault Memory" to check for stored DTC or the corresponding diagnostic repair procedure DIAGNOSTIC MODE 03 - READ DTC MEMORY .

Switch the ignition off.

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.

Switch the ignition off.

CAMSHAFT POSITION SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment 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".
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 PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to appropriate service information.

Disconnect the Camshaft Position (CMP) Sensor -G40- electrical harness connector -1-.

Scheme 444

Switch the ignition on.

Using a multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector terminals 1 to 3 for voltage.

Scheme 445

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.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector to the Motronic Engine Control Module (ECM) electrical harness connector T60 for an open circuit.

Scheme 446

Specified value: 1.5 ohms Max.

If the specified value was not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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 appropriate service information.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Install the engine cover with air filter. Refer to appropriate service information.

Final procedures

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

1. Check the DTC memory «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code «READINESS CODE»(ref-505767-S30254499902012100100000) .

SPEED SIGNAL, CHECKING

The following procedure requires a test drive. Observe all safety precautions.

Special tools and workshop equipment required

1. multimeter.
2. Wiring diagram.

Test requirements

1. The Speedometer -G21- OK.
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.
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 PRELIMINARY CHECK

Start diagnosis

Connect the scan tool.

Perform a road test with a vehicle speed greater than 5 Km/h.

Using the scan tool, Check the vehicle speed

Compare the vehicle speed on the scan tool to the Speedometer -G21-.

Specified value: a difference of no greater than 10%.

If the specified value was not obtained or no speed was displayed

Check the wiring from the Motronic Engine Control Module (ECM) -J623- to the Instrument Cluster Control Module -J285- for an open circuit, Short to Battery (+), or to Ground (GND).

Check the wiring connection for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

CATALYTIC CONVERTER, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Special tools and workshop equipment required

1. Generic scan tool

Test requirements

1. Battery voltage at least 12.5 volts.
2. Oxygen Sensors OK.
3. No leaks or damage to exhaust system.

Function test

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

End diagnosis and switch the ignition off.

If the specified values are exceeded

Check the exhaust system for leaks.

If necessary, repair the leak in the exhaust system.

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

Generate readiness code. Refer to READINESS CODE .

If no leaks are found in the exhaust system

Replace the catalytic converter with front exhaust pipe. Refer to the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

TURBOCHARGER, G-CHARGER

Note. Charge air system must be properly sealed. Always replace self-locking nuts. Charge air hoses and pipes as well as their connections must be free of oil and grease before re-installing. Do not assemble charge air hoses and lines with lubricants containing oils, only coat with water (without additives) if necessary. Note installation marks on hoses and components. All hose connections for charge air system are secured by spring-type clamps or by connector couplings. Install only approved clamps for securing hose connections. Pliers for spring clamps or hose clamp pliers are recommended for installing spring clamps. For connector couplings, always note the following points

Disengage connector coupling by pulling securing clip -arrow-.

Disconnect hose and pipe without the assistance of tools.

When assembling, make sure the retaining tabs -A- are engaged securely.

Scheme 447

Before screwing on oil supply line, fill turbocharger with engine oil at filler tube.

After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.

CHARGE AIR PRESSURE SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment 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. On vehicles with automatic transmission, selector lever in 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 PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to appropriate service information.

Test sequence

Disconnect the Charge Air Pressure Sensor -G31- electrical harness connector -arrow-.

Scheme 448

Start engine and let it run at idle.

Using a multimeter, check the Charge Air Pressure Sensor -G31- electrical harness connector terminals 1 to 3 for voltage.

Specified value: min. 4.5 V

Switch the ignition off.

If the specification was obtained

Replace the Charge Air Pressure Sensor -G31-.

If the specification 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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, check the Charge Air Pressure Sensor -G31- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T94 terminals for an open circuit according to 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).

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 and if the voltage supply was OK

Replace the Charge Air Pressure Sensor -G31-.Refer to appropriate service information.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Install the engine cover with air filter. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

TURBOCHARGER RECIRCULATING VALVE, CHECKING

Special tools and workshop equipment 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. On vehicles with automatic transmission, selector lever in 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 PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to the appropriate service information.

Checking internal resistance

Disconnect the Turbocharger Recirculating Valve -N249- electrical harness connector -2-.

Scheme 449

Using a multimeter, check the Turbocharger Recirculating Valve -N249- terminals 1 to 2 for resistance.

Specified value: 13.6 +/- 5 ohms (at room temp.)

If the specification was not obtained

Replace the Turbocharger Recirculating Valve -N249-. Refer to the appropriate service information.

If the specification was obtained

Checking Voltage supply

Using a multimeter, check the Turbocharger Recirculating Valve -N249- electrical harness connector terminal 1 to Ground (GND).

Scheme 450

Operate the engine briefly.

Specified value: battery voltage.

Switch the ignition off.

If the specified value 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 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 Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Using a multimeter, check the Turbocharger Recirculating Valve -N249- electrical harness connector terminal 2 to Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 for an open circuit.

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 the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Install the engine cover with air filter. Refer to the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

WASTEGATE BYPASS REGULATOR VALVE, CHECKING

Special tools and workshop equipment 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. On vehicles with automatic transmission, selector lever in 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 PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to the appropriate service information.

Checking internal resistance

Disconnect the Wastegate Bypass Regulator Valve -N75- electrical harness connector -1-.

Using a multimeter, check the Wastegate Bypass Regulator Valve -N75- terminals 1 to 2 for resistance.

Specified value: 20 to 30 ohms (at room temp.)

If the specification was not obtained

Replace the Wastegate Bypass Regulator Valve -N75-. Refer to the appropriate service information.

If the specification is obtained

Checking Voltage supply

Using a multimeter, check the Wastegate Bypass Regulator Valve -N75- electrical harness connector terminal 1 to Ground (GND).

Operate the engine briefly.

Specified value: battery voltage.

Switch the ignition off.

If the specification was not obtained

Check the wiring for a short circuit to Battery positive (+) or an open circuit.

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

If necessary, repair the wiring connection.

If no malfunction is found in the 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 Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Using a multimeter, check the Wastegate Bypass Regulator Valve -N75- electrical harness connector terminal 2 to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 for an open circuit.

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 the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Install the engine cover with air filter. Refer to the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

ENGINE COOLANT TEMPERATURE SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment required

1. Generic scan tool
2. Multimeter
3. 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".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. Ignition switched off.
8. Engine cold.

Test procedure

Start diagnosis

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-. Refer to the appropriate service information

Checking internal resistance

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

Scheme 451

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

Specified values

If any of the specified values was not obtained

Replace the Engine Coolant Temperature (ECT) Sensor - G62-. Refer to appropriate service information.

ENGINE COOLANT TEMPERATURE SENSOR ON RADIATOR, CHECKING

Note. Use only gold-plated terminals when servicing terminals in the electrical harness connector of Engine Coolant Temperature (ECT) Sensor (on Radiator) -G83-.

Special tools and workshop equipment 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".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. Ignition switched off.
8. Engine cold.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK .

Start diagnosis

Checking internal resistance

Disconnect the Engine Coolant Temperature (ECT) Sensor (on Radiator) -G83- electrical harness connector -1-.

Scheme 452

Using a multimeter, check the Engine Coolant Temperature (ECT) Sensor (on Radiator) -G83- terminals 1 to 2 for resistance.

Use the chart below for the specified values

Specified values

If any of the specified values was not obtained

Replace the Engine Coolant Temperature (ECT) Sensor (on Radiator) -G83-. Refer to the appropriate service information.

If any of the specified values was obtained

Checking wiring

If the manufacturers test box is being used, perform the following step.

Install the test box, refer to the appropriate service information.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Using a Multimeter --, check the Engine Coolant Temperature (ECT) Sensor (on Radiator) -G83- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T94 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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Final procedures

After 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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

ENGINE SPEED SENSOR, 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 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".
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.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start diagnosis

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.

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

Scheme 453

Specified value: 450 to 1200 ohms

If the specified value is not obtained

Replace the Engine Speed (RPM) Sensor -G28-. Refer to appropriate service information.

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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

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 T60 terminals for an open circuit.

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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. Refer to appropriate service information.

If the sensor wheel is OK

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

EVAPORATIVE PURGE REGULATOR VALVE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, refer to the applicable wiring diagram.

Special tools and workshop equipment required

1. multimeter
2. Wiring diagram.

Test requirements

1. The Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- fuse OK.
2. The ignition switched off.

Note. Voltage for the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- is supplied via the Motronic Engine Control Module (ECM) Power Supply Relay -J271-.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to appropriate service information.

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

Scheme 454

Checking internal resistance

Using a multimeter, check the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- terminals 1 and 2 for resistance.

Specified value: 22.0 to 30.0 ohms.

If the specified value is not obtained

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

If the specification is obtained

Checking voltage supply

Using a multimeter, check the electrical harness connector terminal 1 to 2 for voltage.

Operate the starter briefly.

Specified value: battery voltage.

If the specified value was not obtained

Using a multimeter, check the electrical harness connector terminal 1 for voltage.

Operate the starter briefly.

Specified value: battery voltage.

If the specified value is not obtained

Check the wiring connection from the electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- terminal 2/87 for an open circuit.

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

If necessary, repair the wiring connection.

If the specified value was obtained

Check Ground (GND) activation

Using a multimeter, check the electrical harness connector for voltage.

Operate the starter briefly.

Specified value: battery voltage.

Switch the ignition off.

If the specified value was not obtained

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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, check the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- electrical connector terminal 2 to Motronic Engine Control Module (ECM) -J623- electrical connector T60 for an open circuit.

Specified value: 1.5 ohms max.

If the specification is not obtained

Check the wiring for a short circuit to Battery positive (+) or an open circuit.

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

If necessary, repair the wiring connection.

If the specification was obtained

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Install the engine cover with air filter. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

EVAPORATIVE SYSTEM, CHECKING FOR LEAKS

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Perform a preliminary check to verify the condition: PRELIMINARY CHECK .

Special tools and workshop equipment required

1. Smoke tester
2. Evaporative and fuel supply system vacuum hose and line routing diagram

Test procedure

Using a smoke tester, check the evaporative emission system for leaks.

Note. Always follow the manufacturers directions for the proper installation and operation of the smoke tester being used.

Note. Secure all hose connections using hose clamps appropriate for the model type. Replace seals and gaskets when performing repair work.

If a leak is detected

Check the fuel filler cap seal for damage and for proper installation. Replace if necessary.

Check the seals under the locking flanges and that the union nuts are properly tightened on the fuel tank.

Check all hose connections of the evaporative system and replace or repair any leaking lines.

Repair or replace any damaged component.

If no leaks are found

Erase the DTC memory if a DTC was set. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY

Perform a road test to verify repair.

If a DTC was set and does not return

Repair complete, generate readiness code. Refer to READINESS CODE

If the DTC does return and no leaks are found in the evaporative and fuel supply system

Check the DTC memory for any DTC codes pertaining to the evaporative and fuel supply systems. If a DTC is stored, perform the diagnostic test procedure for the suspected component.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

EVAPORATIVE EMISSION CANISTER SYSTEM, CHECKING FOR PROPER SEAL

Special tools and workshop equipment required

1. Smoke tester.
2. For Evap or fuel supply system concerns, refer to the appropriate service information.

Note. Secure all hose connections using hose clamps appropriate for the model type Replace seals and gaskets when performing repair work.

Leak checking

Using a Smoke tester, check the Evaporative Emission (EVAP) canister system for leaks.

Note. Always follow the manufacturers directions for the proper installation and operation of the Smoke tester being used.

If a leak is detected

Check the fuel filler cap seal for damage and for proper installation. Replace if necessary.

Check the seals under the locking flanges and the union nuts are properly tightened on the fuel tank.

Check all hose connections of the fuel supply system and replace or repair any leaking lines.

Check all hose connections of the EVAP system and replace or repair any leaking lines.

Repair or replace any damaged component.

If no leaks are found in the EVAP and Fuel Supply System

Erase the DTC memory if a DTC was set. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to verify repair.

If a DTC was set and does not return

Generate readiness code. Refer to READINESS CODE .

If the DTC does return and no leaks are found in the EVAP and Fuel Supply System

Check the DTC memory for any DTC codes pertaining to the EVAP and Fuel Supply Systems. If a DTC is stored, perform the diagnostic test procedure for the suspected component. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY .

FUEL INJECTORS, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment required

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

Test requirements

1. The Engine Speed (RPM) Sensor -G28- 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.

Observe safety precautions.

Observe rules for cleanliness.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start diagnosis

Remove the engine cover and air intake duct. Refer to appropriate service information.

Disconnect the 8 pin connector from the fuel injector assembly harness (located just below and to the right of the electronic throttle motor assembly).

Using a multimeter connected to ground, check terminals 2, 4, 6, 8 for the correct voltage.

Specified value: 22 - 25 V.

If voltage is below specification

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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, check the Fuel Injector -- electrical harness connector terminals 2, 4, 6, 8 to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open or short to ground circuit.

Specified values: 1.5 ohms max. for wire continuity, and for circuit to ground check; Infinity or "OL" is displayed

If the specification is not obtained

Check the wiring for an open, high resistance or short to ground.

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

If necessary, repair the faulty wiring connection.

If voltage is within specification

Checking internal resistance

Using a multimeter, check the Fuel Injector -- electrical terminals (1 to 2 for N30, 3-4 for N31, 5-6 for N32 or 7 to 8 for N33) for resistance.

Specified value: 1.4 - 2.6 ohms (at approx. 20° C)

If the specified value was not obtained

Replace the malfunctioning Fuel injector(s). Refer to appropriate service information.

If the specified value was obtained

Checking activation and wiring

Connect a diode test lamp (12V) from Battery + to the injector harness connector terminal (1 for N30, 3 for N31, 5 for N32 or 7 for N33) of the Fuel Injector -- to be tested.

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

LED should flicker.

Switch the ignition off.

If LED does not flicker

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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, check the Fuel Injector -- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open circuit.

Specified value: 1.5 ohms Max.

If the specification is not obtained

Check the wiring for an open, high resistance or short to battery or ground.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Install the engine cover with air filter. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

FUEL PRESSURE SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment required

1. multimeter
2. Wiring diagram.

Test requirements

1. The Fuel Pump (FP) Control Module -J538- OK.
2. The Motronic 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 PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to appropriate service information.

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-. Refer to appropriate service information.

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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, check the Fuel Pressure Sensor -G247- electrical harness connector terminals to the Motronic 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 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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Install the engine cover with air filter. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

LOW FUEL PRESSURE SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment required

1. multimeter.
2. Wiring diagram.

Test requirements

1. The Fuel Pump (FP) Control Module -J538- OK.
2. The Motronic 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 PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to appropriate service information.

Checking voltage

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

Scheme 455

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-. Refer to appropriate service information.

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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, check the Low Fuel Pressure Sensor -G410- electrical harness connector terminals to the Motronic 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 specified value was Not obtained

Check the wiring for an open, high resistance, short to Battery (+) or 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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Install the engine cover with air filter. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

FUEL PRESSURE REGULATOR VALVE, CHECKING

Special tools and workshop equipment required

1. multimeter.
2. Wiring diagram.

Test requirements

1. The Engine Component Power Supply Relay -J757- OK.
2. The Motronic 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 PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to appropriate service information.

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 456

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

If the specified value was not obtained

Replace the Fuel Pressure Regulator Valve -N276-. Refer to appropriate service information.

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.

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- terminal 2/87 for a short circuit to Ground (GND), or an open circuit.

Switch the ignition off.

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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, check the Fuel Pressure Regulator Valve -N276- electrical harness connector terminals to the Motronic 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 Battery (+), or an open circuit.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Install the engine cover with air filter. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

FUEL PUMP DELIVERY QUANTITY, CHECKING

Special tools and workshop equipment required

1. Switched remote control (jumper).
2. multimeter.
3. Electrical connector test lead set.
4. Fuel pressure test set.
5. Measuring container, fuel-resistant.

Test conditions

1. Battery voltage 12.5 V
2. Fuel filter OK
3. Fuel tank at least 1 / 4 filled.
4. Fuel pressure regulator OK.
5. Ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start diagnosis

Remove the fuel filler cap from fuel filler tube.

Remove rear seat bench. Refer to appropriate service information.

Remove the floor sealing cover -1-.

Scheme 457

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

Scheme 458

Connect a switched remote control (jumper) to terminal -1- of the fuel delivery unit and to vehicle battery (+).

Connect a jumper wire from terminal -5- of the fuel delivery unit to vehicle Ground (GND).

Scheme 459

Disconnect the fuel return line -arrow- by pressing release buttons.

Scheme 460

Connect a fuel line from the fuel pressure test set to the disconnected fuel return line and hold it in the measuring container.

Scheme 461

Press the switch on the remote control (jumper) and operate the fuel pump for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in the diagram (cm 3 /30 sec.).

Scheme 462

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 plugged.
3. Fuel pump faulty.

If necessary, repair any pinched or plugged lines.

If the filter is restricted

Replace the fuel filter. Refer to appropriate service information.

If the fuel pump is faulty

Replace the fuel pump. Refer to appropriate service information.

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

Install the rear seat bench. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

FUEL PUMP CONTROL MODULE, CHECKING

Special tools and workshop equipment required

1. multimeter
2. Wiring diagram.

Test requirements

1. Fuse -SF6- 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".
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 customer's complaint. Refer to PRELIMINARY CHECK

Start diagnosis

Remove rear seat assembly. Refer to the appropriate service information

Checking voltage

Switch the ignition on.

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

Specified value: Battery voltage

Switch the ignition off.

If the specified value was not obtained

Check the Fuel Pump (FP) Control Module -J538- wiring harness terminal T10k/1 to the Battery -- B (+) terminal for an open circuit or short to Ground (GND).

Check the Fuel Pump (FP) Control Module -J538- wiring harness terminal T10k/2 to GND for an open circuit or short to B+.

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 connection for voltage.

Specified value: about 12.5 V

Switch the ignition off.

If the specified value was not obtained

Check the Fuel Pump (FP) Control Module -J538- wiring harness terminal T10k/3 to Fuse 1 (on fuse panel C) -SC1- harness connector terminal T94 / 42 for an open circuit or 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 Fuel Pump (FP) Control Module -J538- wiring harness terminal T10k/2 to chassis ground for resistance.

Specified value: 1.5 ohms maximum.

If the specified value was not obtained

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

Replace the Fuel Pump (FP) Control Module -J538-. Refer to the appropriate service information.

Perform a road test to verify repair.

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 the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

IGNITION COIL WITH POWER OUTPUT STAGE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment required

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

Test requirements

1. The Ignition Coils with Power Output Stage - N70, N127, N291, N292- 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.
5. Battery voltage at least 12.5 volts.
6. All electrical consumers such as, lights and rear window defroster, switched off.
7. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
8. A/C switched off.
9. Ground (GND) connections between engine/transmission/chassis OK.
10. Ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to appropriate service information.

Remove the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness screws -1-.

Scheme 463

Disconnect the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness connectors -arrows- from the Ignition Coils with Power Output Stage -N70, N127, N291, N292-.

Scheme 464

Checking voltage supply

Switch the ignition on.

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

Scheme 465

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 an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was not obtained

Check the wiring connection for an open circuit.

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

Disable the power supply to the Fuel Injectors -N30, N31, N32, N33- by removing Fuse 29 (on fuse panel B) from the fuse holder SB29, in the E-box, plenum chamber.

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 Coils with Power Output Stage -N70, N127, N291, N292-. Refer to appropriate service information.

If the 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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

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

Check the wiring connection for an open circuit.

Check the wiring connection for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

If the specified values were obtained

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Connect the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness connectors -arrows- to the Ignition Coils with Power Output Stage -N70, N127, N291, N292-.

Scheme 466

Install the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness screws -1-.

Install the engine cover with air filter. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

INTAKE AIR TEMPERATURE SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

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 PRELIMINARY CHECK .

Start diagnosis

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 engine cover. Refer to the appropriate service information.

Checking internal resistance

Disconnect the Intake Air Temperature (IAT) Sensor -G42- electrical harness connector -1-.

Scheme 467

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

Specified values

If any of the specified values are not obtained

Replace the Intake Air Temperature (IAT) Sensor -G42-. Refer to the appropriate service information.

INTAKE AIR SWITCH-OVER VALVE, CHECKING

Special tools and workshop equipment required

1. multimeter.
2. Wiring diagram.

Test requirements

1. The fuse for Intake Air Switch-Over valve -N335- SB7 OK.
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.
5. On vehicles with automatic transmission, selector lever in 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 PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to the appropriate service information.

Checking internal resistance

Disconnect the Intake Air Switch-Over valve -N335- electrical harness connector..

Using a multimeter, check the Intake Air Switch-Over valve -N335- terminals 1 to 2 for resistance.

Specified value: 13.6 +/- 5 ohms (at room temp.)

If the specification was not obtained

Replace the Intake Air Switch-Over valve -N335-. Refer to the appropriate service information.

If the specification was obtained

Checking Voltage supply

Using a multimeter, check the Intake Air Switch-Over valve -N335- electrical harness connector terminal 1 to Ground (GND).

Operate the engine briefly.

Specified value: battery voltage.

Switch the ignition off.

If the specified value 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 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 Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Using a multimeter, check the Intake Air Switch-Over valve -N335- electrical harness connector terminal 2 to Motronic Engine Control Module (ECM) -J623- electrical harness connector T94 for an open circuit.

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 the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Install the engine cover with air filter. Refer to the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

INTAKE FLAP MOTOR/INTAKE MANIFOLD RUNNER POSITION SENSOR, CHECKING

Note. The Intake Manifold Runner Position Sensor is co-housed with the Intake Flap Motor. Replacement of one replaces both.

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment 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".
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 PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to appropriate service information.

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

Scheme 468

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 not obtained

Check and/or repair wiring as required.

If the specified value was obtained

Checking internal resistance

Using a multimeter, check the Intake Flap Motor -V157- /Intake Manifold Runner Position Sensor -G336- electrical terminals 2 to 3 for resistance.

Specified value: 7-25 ohms (at approx. 20° C)

Using a multimeter, check the Intake Manifold Runner Position Sensor -G336- electrical terminals 1 to 3 for resistance.

Specified value: 244 [+/- 40] ohms (at approx. 20° C)

If the specified values were not obtained

Replace the Intake Flap Motor -V157- /Intake Manifold Runner Position Sensor -G336-. Refer to appropriate service information.

If the specified value 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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

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

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Install the engine cover with air filter. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

KNOCK SENSOR 1, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The mounting bolt of Knock Sensor (KS) 1 -G61- tightened to 20 Nm.
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.
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 PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to appropriate service information.

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

Disconnect the Knock Sensor (KS) 1 -G61- electrical harness connector -1-.

Scheme 469

Checking internal resistance

Using a multimeter, check the Knock Sensor -- terminals 1 to 2 for an internal short.

Scheme 470

Specified value: infinity (Infinity).

If the specified value was not obtained

Replace the faulty Knock Sensor (KS) 1 -G61-. Refer to appropriate service information.

If the specified value 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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, Check the Knock Sensor -- electrical harness connector to the Motronic Engine Control Module (ECM)J623 electrical harness connector T60 for an open circuit.

Scheme 471

Specified value: 1.5 ohms Max.

If the specified value was not obtained

Check the wiring connection for an open circuit.

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-. Refer to appropriate service information.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Install the engine cover with air filter. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

KNOCK SENSOR 2, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The mounting bolt of Knock Sensor (KS) 2 -G66- tightened to 20 Nm.
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.
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 PRELIMINARY CHECK

Start diagnosis

Remove the engine cover with air filter. Refer to appropriate service information.

Note. Before disconnecting the Knock Sensor (KS) 2 -G66- electrical harness connectors, mark the component location.

Disconnect the Knock Sensor (KS) 2 -G66- electrical harness connector -2-.

Checking internal resistance

Using a multimeter, check the Knock Sensor (KS) 2 -G66- terminals 1 to 2 for an internal short.

Specified value: infinity (Infinity).

If the specified value was not obtained

Replace the faulty Knock Sensor (KS) 2 -G66-. Refer to appropriate service information.

If the specified value 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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, Check the Knock Sensor (KS) 2 -G66- 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

Check the wiring connection for an open circuit.

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) 2 -G66-. Refer to appropriate service information.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Install the engine cover with air filter. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

LEAK DETECTION PUMP, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment required

1. multimeter
2. Wiring diagram.

Test requirements

1. The Leak Detection Pump (LDP) -V144- fuse OK.
2. The ignition switched off.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start diagnosis

Remove the left rear wheel housing liner. Refer to appropriate service information.

Disconnect the Leak Detection Pump (LDP) -V144- electrical harness connector -2-.

Scheme 472

Checking internal resistance

Using a multimeter, check the Leak Detection Pump (LDP) -V144- for resistance as follows

Scheme 473

If any of the specifications are not obtained

Replace the Leak Detection Pump (LDP) --V144--. Refer to appropriate service information.

If the specified values are obtained

Checking voltage supply

Note. The voltage for the Leak Detection Pump (LDP) --V144-- is supplied via the Fuse 7 (on fuse panel B) -SB7-.

Check the Leak Detection Pump (LDP) --V144-- for voltage.

Using a multimeter, check the Leak Detection Pump (LDP) --V144-- electrical harness connector terminal 3 and ground for voltage.

Scheme 474

Operate the starter briefly.

Specified value: battery voltage.

Switch the ignition off.

If the specified value was not obtained

Using a multimeter, check the Leak Detection Pump (LDP) --V144-- electrical harness connector terminal 3 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- terminal 2/87 for an open circuit.

Specified value: Wire resistance max 1.5 ohms.

If the specification is not obtained

Check the wiring for a short circuit to Battery positive (+) or an open circuit.

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

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 Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, check the Leak Detection Pump (LDP) --V144-- electrical connector terminals to Motronic Engine Control Module (ECM) -J623- electrical connector T94 terminals.

Specified value: 1.5 ohms max.

If the specification is not obtained

Check the wiring for a short circuit to Battery positive (+) or an open circuit.

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

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

Install the left rear wheel housing liner. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

MASS AIR FLOW SENSOR, 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. The Mass Air Flow (MAF) Sensor -G70- fuse 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 PRELIMINARY CHECK

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 -2-.

Ignore arrows

Scheme 475

Start the engine and let it run at idle.

Using a multimeter, check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminal 5 to engine Ground (GND).

Scheme 476

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 5 to the Power Supply Relay (terminal 50) -J682- terminal 2/30 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.

Install the test box.

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

Remove the Motronic Engine Control Module (ECM) -J623-. refer to the appropriate service information.

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 T94 terminals for an open circuit.

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-. Refer to appropriate service information.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

OXYGEN SENSOR AFTER CATALYTIC CONVERTER, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment required

1. Generic scan tool
2. Multimeter
3. Wiring diagram

Test requirements

1. The oxygen sensor properly installed
2. Exhaust system free of leaks
3. The oxygen sensor fuses OK
4. Ground connections between engine/transmission/chassis OK
5. Battery voltage at least 12.5 volts
6. Coolant temperature at least 80° C
7. All electrical consumers switched off
8. Vehicles with automatic transmission, shift selector lever in park or neutral
9. A/C switched off
10. Engine running

Note. The oxygen sensor compares the oxygen content of the outside air with the residual oxygen content in the exhaust gas, and generates a voltage input signal to the engine control module. If oxygen sensor voltage does not fluctuate, the sensor does not respond, or responds too slowly, the following causes are possible: Slits in the oxygen sensor tip are plugged Sensor not up to operating temperature Sensor has been thermally overloaded Transition resistance in signal wire or reference ground connection Sensor has been damaged by electrical contact cleaner or similar contaminant (drawn through signal wire by capillary action due to thermal fluctuation) Sensor has been damaged by exposure to silicone. When using silicone sprays and sealants, silicone residue is drawn into the engine where it passes unburned into the exhaust and can damage the oxygen sensor

Test procedure

Using a generic scan tool, refer to Diagnostic Mode 05 - Read Current System Data.

Note. Mode 05 may not be supported on all systems. On systems where Diagnostic Mode 05 is not supported, refer to Diagnostic Mode 6 for oxygen sensor monitoring test results.

Review the mode data test results.

If any of the test results indicate a monitor failure

Refer to the monitor support documentation as indicated in the mode test procedure to diagnose and repair the cause of the failure.

If the test results indicate no monitor failures

Checking primary voltage

Disconnect the oxygen sensor electrical harness connector. Refer to the service information for removal and installation procedures.

Switch ignition on.

Using a multimeter, measure the voltage between the sensor signal and reference ground circuits.

1. Specification: 0.400 to 0.500 V

Switch ignition off.

If specified value is not obtained

Check the oxygen sensor wiring and connections.

If specified value is obtained

Replace the oxygen sensor. Refer to the appropriate service information for removal and installation procedures.

Checking wiring and connections

Remove the engine control module. Refer to the service information for removal and installation procedures.

Using a multimeter, measure the resistance of the signal and reference ground circuits between the oxygen sensor and the engine control module. Refer to the applicable wiring diagram.

Specified value: 1.5 ohms max.

If the specification was not obtained

Check the circuits for a short to each other, short to battery voltage, and short to ground.

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

Repair the wiring or connection as necessary.

If no malfunction is detected in the wiring

Replace the engine control module. Refer to the service information for removal and installation procedures.

Final procedures

After 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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

HEATED OXYGEN SENSOR HO2S, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

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. The Heated Oxygen Sensor (HO2S) -G39- fuse OK.
2. The Oxygen Sensor (O2S) Heater -Z19- before catalytic converter OK. Refer to «OXYGEN SENSOR O2S HEATER, CHECKING»(ref-505767-S23713360522012100100000) .
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. Exhaust system between catalytic converter and cylinder head properly sealed.
8. Coolant Temperature at least 80° C.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start diagnosis

Connect scan tool.

Start the engine and let it run at idle.

Select "Diagnostic mode 6: Check test results of components that are not continuously monitored".

Select "Test-ID 01: Oxygen sensor monitoring before catalytic converter".

Select "Test-ID 131: Dynamic test".

Check the specified values at idle.

If specified values are obtained

End diagnosis and switch the ignition off.

If the specified values are not obtained

Checking primary voltage

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

Scheme 477

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

Scheme 478

Specified value: 0.400 to 0.500 Volts

Switch the ignition off.

If the specified value was not obtained

Replace the Heated Oxygen Sensor (HO2S) -G39-. Refer to the appropriate service information.

If the specified value 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 Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T94 terminals for an open circuit.

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

OXYGEN SENSOR O2S BEHIND THREE WAY CATALYTIC CONVERTER, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

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

Special tools and workshop equipment required

1. Generic scan tool
2. multimeter.
3. Wiring diagram.

Test requirements

1. The Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- fuse Ok.
2. Oxygen Sensor O2S Behind Three Way Catalytic Converter Heater - Z29- 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, selector lever in position "P" or "N".
6. A/C switched off.
7. Ground (GND) connections between engine/transmission/chassis OK.
8. Exhaust system between catalytic converter and cylinder head properly sealed.
9. Coolant Temperature at least 80° C.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start diagnosis

Connect scan tool.

Start the engine and let it run at idle.

Select "Diagnostic mode 6: Check test results of components that are not continuously monitored".

Select "Test-ID 02: Oxygen sensor monitoring behind catalytic converter".

Select following Test-IDs.

Check the specified values at idle.

If the specified values are obtained

End diagnosis and switch ignition off.

If the specified values are not obtained

Remove the right vehicle floor cover -arrows-. Refer to the appropriate service information.

Scheme 479

Checking primary voltage

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

Scheme 480

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 481

Specified value: 0.400 to 0.500 Volts

Switch the ignition off.

If the specified value was not obtained

Replace the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130-. Refer to the appropriate service information.

If the specified value 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 Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

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- electrical harness connector T94 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 Battery (+), or an open circuit.

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Install the right vehicle floor cover -arrows-. Refer to the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

OXYGEN SENSOR O2S HEATER, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Oxygen Sensor (O2S) Heater -Z19- is part of Heated Oxygen Sensor (HO2S) -G39- and cannot be replaced separately.

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 PRELIMINARY CHECK .

Start diagnosis

Remove the engine cover with air filter. Refer to the appropriate service information.

Checking internal resistance

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

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-. Refer to the appropriate service information.

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.

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 the appropriate service information.

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

Generate readiness code. Refer to READINESS CODE .

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 the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000)

OXYGEN SENSOR O2S 1 HEATER BEFORE CATALYTIC CONVERTER, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Note. Oxygen Sensor (O2S) 1 Before Catalytic Converter Heater - Z29- is part of Oxygen Sensor (O2S) Before Three Way Catalytic Converter -G130- and cannot be replaced separately.

Special tools and workshop equipment required

1. multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB21- 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 PRELIMINARY CHECK .

Start diagnosis

Remove right cover from vehicle underbody. Refer to the appropriate service information.

Checking internal resistance

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

Scheme 482

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

Scheme 483

Specified value: 2.5 to 14.0 ohms (at approx. 20° C)

If the specification was not obtained

Replace the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. Refer to the appropriate service information.

If the specification was obtained

Checking voltage supply

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.

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, 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 the appropriate service information.

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

Specified value: 1.5 ohms max.

If the specification was not obtained

Check the wiring for a open circuit or short to 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

Generate readiness code. Refer to READINESS CODE .

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 the appropriate service information.

Final procedures

After 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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

CAN BUS TERMINAL RESISTANCE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment 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.
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.

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-.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start diagnosis

Disconnect the Data Bus On Board Diagnostic Interface -J533- electrical harness connector.

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

Using a multimeter, check the Data Bus On Board Diagnostic Interface -J533- electrical harness connector terminals 6 to 16 for resistance.

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

If the specified value was not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

If the specified value 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 Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Using a multimeter, check the Data Bus On Board Diagnostic Interface -J533- electrical harness connector to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T94 for resistance.

Specified value: 1.5 ohms Max.

If the specified value was not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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

Replace the Data Bus On Board Diagnostic Interface -J533-. Refer to the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

CAN BUS INSTRUMENT CLUSTER TO DATA BUS OBD INTERFACE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment 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.
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.

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-.

Test procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start diagnosis

Disconnect the Instrument Cluster Control Module -J285- electrical harness connector.

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

Using a multimeter, check the Instrument Cluster Control Module -J285- electrical harness connector terminals T32/29 to T32/30 for resistance.

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

If the specified value was not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

If the specified value 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 Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Using a multimeter, check the Data Bus On Board Diagnostic Interface -J533- electrical harness connector to the Instrument Cluster Control Module -J285- electrical harness connector T32 for resistance.

Specified value: 1.5 ohms Max.

If the specified value was not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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

Replace the Instrument Cluster Control Module -J285-. Refer to the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

TCM TO ECM CAN BUS TERMINAL RESISTANCE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment required

1. Multimeter
2. Wiring diagram

Test requirement

1. A CAN malfunction was recognized
2. Battery voltage at least 12.5 volts
3. Engine control module fuses OK
4. Ignition switched off

Test procedure

Remove the transmission control module. Refer to the appropriate service information for removal and installation procedures.

Disconnect the transmission control module electrical harness connector.

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

Repair as necessary.

Note. The ECM must remain connected for the following step. The central terminal resistor is located in the ECM.

Using a multimeter, check the Direct Shift Gearbox (DSG) Mechatronic -J743- electrical harness connector terminals 10 to 15 for resistance.

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

If the specified value was not obtained

Checking wiring

Remove the engine control module. Refer to the appropriate service information for removal and installation procedures.

Using a multimeter, check each of the CAN bus circuits between the transmission control module and the engine control module. Refer to the applicable wiring diagram.

Check each CAN circuit for a short to ground, short to voltage, open circuit or high resistance.

Repair as necessary.

If the specified resistance value was not obtained and no malfunction is found in the wiring

Replace the engine control module. Refer to the appropriate service information for removal and installation procedures.

If the specified resistance value was obtained

Remove the engine control module. Refer to the appropriate service information for removal and installation procedures.

Check each CAN circuit for a short to ground, short to voltage, open circuit or high resistance.

Repair as necessary.

If no malfunction is found in the wiring

Replace the transmission control module. Refer to the appropriate service information for removal and installation procedures.

Final procedures

After 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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

THROTTLE POSITION SENSOR/ACCELERATOR PEDAL POSITION SENSOR 2, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment 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".
5. A/C switched off.
6. 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 procedure

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start diagnosis

Remove the drivers side storage compartment. Refer to the appropriate service information.

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

Scheme 484

Checking voltage supply and wiring

Switch the ignition on.

Using a multimeter, check the following wiring connections for voltage.

Scheme 485

Switch the ignition off.

If the specification was not obtained

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 Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Using a multimeter, check the Throttle Position (TP) Sensor -G79- /Accelerator Pedal Position Sensor 2 -G185- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical connector T94 for an open circuit.

Scheme 486

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 the Throttle Position (TP) Sensor -G79- /Accelerator Pedal Position Sensor 2 -G185-. Refer to the appropriate service information.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate service information.

Install the drivers side storage compartment. Refer to the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

THROTTLE VALVE CONTROL MODULE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment 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".
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 Motronic 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 PRELIMINARY CHECK

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 487

Checking resistance

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.

Scheme 488

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

If the specification was not obtained

Replace the Throttle Valve Control Module - J338-. Refer to appropriate service information.

If the specification was obtained

Check the voltage supply of the Throttle Valve Control Module -J338- to the Motronic Engine Control Module (ECM) -J623-.

Checking voltage supply and wiring

Switch the ignition on.

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.

Scheme 489

Specified value: at least 4.5 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.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, check the Throttle Valve Control Module -J338- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open circuit according to the wiring diagram.

Scheme 490

Specified value: 1.5 ohms max.

If the specification is not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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 and if the voltage supply was not OK

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

VOLTAGE SUPPLY, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment 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".
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 PRELIMINARY CHECK

Start diagnosis

Remove the Motronic Engine Control Module (ECM) Power Supply Relay -J271-. Refer to appropriate service information.

Checking voltage

Using a multimeter, check the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 3/86 to Ground (GND).

Specified value: battery voltage.

If the specified value was not obtained

Check the wiring connections from the Battery to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 3/86 for an open circuit or a short circuit.

Check the wiring connections 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.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, check the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 3/86 to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T94 terminal 92 for resistance.

Specified value: 2.0 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

Checking activation

Switch the ignition on.

Using a multimeter, check the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 4/85 to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T94 terminal 69 for voltage.

Switch the ignition off.

Specified value: 0.5 V Max.

If the specified value was obtained

Replace the Motronic Engine Control Module (ECM) Power Supply Relay -J271-. Refer to appropriate service information.

If the specified value was not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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 not OK

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

POWER SUPPLY RELAY, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

For wiring diagrams, component locations, and connector views, Refer to the applicable wiring diagram.

Special tools and workshop equipment 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".
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 PRELIMINARY CHECK

Start diagnosis

Remove the Power Supply Relay (terminal 50) -J682-. Refer to appropriate service information.

Checking voltage

Using a multimeter, check the Power Supply Relay (terminal 50) -J682- socket 2/30 to Ground (GND).

Specified value: battery voltage.

If the specified value was not obtained

Check the wiring connections from the Battery to the Power Supply Relay (terminal 50) -J682- socket 2/30 for an open circuit or a short circuit.

Check the wiring connections 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.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

Using a multimeter, check the Power Supply Relay (terminal 50) -J682- socket 6/85 to engine ground (GND) for resistance.

Specified value: 2.0 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to Battery (+), or an open circuit.

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

Checking activation

Switch the ignition on.

Using a multimeter, check the Power Supply Relay (terminal 50) -J682- socket 8/87 to the Starter -B- electrical connector for voltage.

Switch the ignition off.

Specified value: at least 12.5 volts.

If the specified value was not obtained

Replace the Power Supply Relay (terminal 50) -J682-. Refer to appropriate service information.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

ENGINE CONTROL MODULE, REPLACING

Removing

Special tools and workshop equipment required

1. Heat gun.
2. locking pliers

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

Refer to the appropriate service information.

ENGINE COMPONENT POWER SUPPLY RELAY, CHECKING

Special tools and workshop equipment required

1. multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB5- OK.
2. Fuse -SB7- OK.
3. Motronic Engine Control Module (ECM) Power Supply Relay -J271- OK
4. Battery voltage at least 12.5 volts.
5. All electrical consumers such as, lights and rear window defroster, switched off.
6. Vehicles with automatic transmission, selector lever in position "P" or "N".
7. A/C switched off.
8. Ground (GND) connections between engine/transmission/chassis OK.
9. Ignition switched off.

Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK .

Start diagnosis

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 Component Power Supply Relay -J757- socket 1/30 to the Generator (GEN) -C- B (+) terminal 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 activation

Switch the ignition on.

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

Switch the ignition off.

Specified value: 12.5. battery voltage.

If the specified value was not obtained

Using a multimeter, check the Engine Component Power Supply Relay -J757- socket 3/86 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 2/87 for an open circuit or 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 Engine Component Power Supply Relay -J757- socket 5/85 to the Engine Control Module (ECM) -J623- electrical harness connector terminal T94/28 for resistance.

Specified value: 1.5 ohms.

If the specified value was not obtained

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

Replace the Engine Component Power Supply Relay -J757-.

Perform a road test to verify repair.

If the fault does not return

Generate readiness code. Refer to READINESS CODE .

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 the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

For all Automatic Transmission - Gears, hydraulic controls, Technical Data. Refer to the appropriate service information.

For all Automatic Transmission - Gears, hydraulic controls component locations. Refer to the appropriate service information.

For all Automatic Transmission - Gears, Hydraulic controls removal/installation procedures and torque specifications. Refer to the appropriate service information.

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 and are available for rental or 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. 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! Always switch ignition off before disconnecting or connecting Battery -A-, failure to do so may damage the Direct Shift Gearbox (DSG) Mechatronic -J743-. If special testing equipment is required during road test, note the following

SELECTOR LEVER VOLTAGE SUPPLY, CHECKING

Special tools and workshop equipment required

1. multimeter.
2. Wiring diagram.

Test requirements

1. The Direct Shift Gearbox (DSG) Mechatronic -J743- fuses OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Selector lever in "P".
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 PRELIMINARY CHECK

Start diagnosis

Remove the selector mechanism, far enough to gain access to the Selector Lever -E313- electrical harness connector -A-. Refer to the appropriate service information.

Disconnect the Selector Lever -E313- electrical harness connector -A-.

Scheme 491

Checking voltage supply, terminal 30

Using a multimeter, check the Selector Lever -E313- electrical harness connector terminals 10 to 1 for voltage.

Specified value: battery voltage.

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 value was obtained

Checking voltage supply, terminal 15

Using a multimeter, check the Selector Lever -E313- electrical harness connector terminals 9 to 1 for voltage.

Specified value: battery voltage.

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 wiring and voltage were OK

Replace the Selector Lever -E313-. Refer to the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .

VOLTAGE SUPPLY OF DIRECT SHIFT GEARBOX MECHATRONIC, CHECKING

Special tools and workshop equipment required

1. multimeter.
2. Wiring diagram.

Test requirements

1. The Direct Shift Gearbox (DSG) Mechatronic -J743- fuses OK.
2. The Power Supply Relay (terminal 15) - J329- OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. Selector lever in "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 PRELIMINARY CHECK

Start diagnosis

Disconnect the Direct Shift Gearbox (DSG) Mechatronic -J743- electrical harness connector -1- by rotating counterclockwise.

Scheme 492

Checking voltage supply, terminal 30

Using a multimeter, check the Direct Shift Gearbox (DSG) Mechatronic -J743- electrical harness connector terminals for voltage.

Turn key on

Specified value: battery voltage.

If the specified value was not obtained

Turn key off

Check the wiring connection for an open circuit.

Check the wiring connection for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

If the wiring and voltage were OK

Voltage supply, terminal 15

Using a multimeter, check the Direct Shift Gearbox (DSG) Mechatronic -J743- electrical harness connector terminals for voltage.

Turn key on

Specified value: battery voltage.

If the specified value was not obtained

Turn key off

Check the wiring connection for an open circuit.

Check the wiring connection for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring connection.

If the wiring and voltage were OK

Replace Direct Shift Gearbox (DSG) Mechatronic -J743-. Refer to the appropriate service information.

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»(ref-505767-S29185418222012100100000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-505767-S33599052192012100100000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-505767-S30254499902012100100000) .