2.5L - Generic Scan Tool - Engine Code(s): Bpr & Bps (Hatchback): Other Volkswagen Beetle A4 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 data bus 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 data bus 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 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.

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

Prior to 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 DTCs.

If other DTCs are stored

Repair these DTCs first before performing the following procedure.

If no other DTCs 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 sir 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.

FUEL PUMP VOLTAGE SUPPLY, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Electrical connector test lead set.

Test conditions

1. Battery voltage 12.5 V.
2. Fuel filter OK.
3. Ignition switched off.

Test procedure

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

Start diagnosis

Remove rear seat bench. Refer to the Repair information.

Test procedure for Fuel Delivery Unit

Remove the floor sealing cover below rear seat to access the Fuel Delivery Unit (fuel pump).

Disconnect the harness connector from the Fuel Delivery Unit.

Connect the multimeter positive lead to terminal 1 of the Fuel Delivery Unit harness connector.

Connect the multimeter ground to the Battery Negative terminal.

Crank the engine and note voltage displayed on multimeter during crank. Voltage should be within 2.5 volts of battery voltage.

Turn the ignition switch OFF.

If voltage is below specification

Check voltage supply from the J17 Fuel Pump relay.

If voltage is within specification

Connect the multimeter ground lead to terminal 5 of the Fuel Delivery Unit harness connector.

Connect the multimeter positive lead to Battery Positive

Crank the engine and note voltage displayed on multimeter during crank. Voltage should be within 2.0 volts of battery voltage.

Turn the ignition switch OFF.

If voltage is below specification

Check for open ground circuit or poor ground connection. Repair as necessary.

If voltage is within specification

Replace the Fuel Delivery Unit (Fuel Pump). Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

FUEL PUMP PRESSURE, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Fuel line adapter setV.A.G. 1318/17A. These tools may be substituted with an equivalent aftermarket tool and are also available for rental or purchase through Volkswagen.
3. In line Fuel pressure gauge with shutoff. (high pressure).

Test conditions

1. Battery voltage 12.5 V
2. Function and voltage supply for the Fuel Pump is OK.
3. Fuel tank at least 1 / 4 filled.
4. Ignition switched OFF.

Test procedure

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

Start diagnosis

Disconnect fuel supply line at the supply location and catch any fuel coming out with a shop towel. Refer to the Repair information for location.

Note. Pull circlip upward to unlock fuel line

Install a fuel pressure gauge with appropriate adapters.

Open shut off valve on fuel gauge.

Switch ignition ON, pause 3 Sec. then OFF, repeatedly until fuel pressure stops increasing pressure.

Read fuel pressure on the gauge.

1. Specified value: 3.5 to 6 bar

If specification is exceeded

Check return line between fuel filter and fuel pump for kinks or blockage.

If no malfunction in fuel return line is found

Pressure relief valve in fuel filter is malfunctioning.

Replace the fuel filter. Refer to the Repair information.

If specified value was Not obtained

Check fuel pressure at the fuel filter between fuel pump and fuel filter using appropriate adapters

Open shut off valve on gauge and start the engine. Allow to idle.

Slowly close the pressure gauge shut off and note the fuel pressure.

1. Pressure must increase to 6 bar.

When 6 bar is reached: Open shut off tap immediately!

If pressure has increased during test

Fuel pump is OK. Pressure relief valve in fuel filter is malfunctioning.

Replace the fuel filter. Refer to the Repair information.

If pressure did not increase

Fuel pump is faulty

Replace the fuel pump. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

FUEL PUMP DELIVERY RATE, CHECKING

Special tools and workshop equipment required

1. Hand held 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 the Repair information.

Remove the floor sealing cover.

Disconnect the electrical harness connector from the fuel delivery unit.

Connect a hand held remote control (jumper) to the pump motor positive terminal of the fuel delivery unit and to vehicle Battery (+). Refer to Wiring Diagrams for identification of terminal.

Connect a jumper wire from pump motor ground terminal of the fuel delivery unit to vehicle Ground.

Disconnect the fuel return line by pressing release buttons. Refer to the Repair information.

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

Press the switch on the hand held 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 /30s).

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

If specified value was Not obtained

Check the following components

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

Repair or replace the above components as necessary.

To replace the fuel filter refer to the Repair information.

To replace the fuel pump refer to the Repair information.

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

Install the rear seat bench. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

EVAP 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. EVAP and Fuel Supply System Vacuum hose and line routing diagram.

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

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

Remove the rear seat bench. Refer to the Repair information.

Remove the floor cover seal.

Inspect the seal under the Fuel Delivery Unit (fuel pump) locking flange for proper sealing. Also check the fuel line connections.

Repair or replace any damaged component.

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

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

Perform a road test to verify repair.

Generate readiness code. Refer to READINESS CODE .

EVAP SYSTEM, CHECKING SEAL

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

Test procedure

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

Start diagnosis

Connect the scan tool.

Start the engine and let run at idle for at least 15 minutes.

Select "Diagnostic mode 8: Tank leak test".

Select the "Test-ID 01: Tank leak test" and check the specified value at idle.

Specified value = Test OK

Note. If the accelerator pedal is depressed during the test, the test will be aborted. To repeat the tank leak-tightness test, switch the ignition off, start the engine again, and let it run at idle.

If the specified value was obtained

Switch the engine OFF. Turn the ignition to ON position, clear fault code, start engine and generate readiness code.

If the specified value was Not obtained

Checking fuel supply and tank ventilation systems for leaks

Ensure the fuel filler cap is properly installed on the fuel tank.

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

Remove the rear seat bench. Refer to the Repair information.

Remove the floor cover seal.

Inspect the seal under the Fuel Delivery Unit (fuel pump) locking flange for proper sealing. Also check the fuel line connections.

Visually check all hose connections of the fuel supply system and replace any leaking lines.

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

Note. Leaks at the lines and components of the fuel tank ventilation system can sometimes be located using a non flammable, environmentally compliant leak detection spray. Initiate the leak diagnosis several times in sequence to build up pressure in the system. At leaking areas, bubbles will form.

Repeat the function test.

If a leak is detected

Perform a visual inspection on the fuel system components and tank ventilation system.

1. Fuel tank.
2. EVAP canister.
3. Fuel lines.
4. Leak Detection Pump (LDP) -V144-.
5. Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-.

Note. Due to the form or function of the components, leaking areas may not always be localized by spraying on the leak detection spray. It may be necessary to clamp off the relevant component using Hose Clamps Up To 25 mm Diameter. and initiate the tank leak detection diagnostic. If the leak is no longer indicated, the component that was clamped off may be faulty. If clamped off directly at the leak detection pump and a leak is still indicated, the leak detection pump itself is leaking.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

EVAP PURGE REGULATOR VALVE, CHECKING

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.

Test procedure

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

Start diagnosis

Disconnect theEvaporative Emission (EVAP) Canister Purge Regulator Valve -N80- electrical harness connector.

Checking internal resistance

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

Scheme 39

Specified value: 14 to 25 ohms.

If the specified value was Not obtained

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

If the specification is obtained

Checking voltage supply

Star the engine.

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

Scheme 40

Specified value: 10.6 volts +/- 2 volts.

Turn the ignition switch OFF.

If the specified value was Not obtained

Leave the multimeter positive lead on terminal 1 and connect the multimeter negative lead to engine ground.

Engine still running.

Specified value: 10.6 volts +/- 2 volts.

Turn the ignition switch OFF.

If the specified value was Not obtained

Remove fuse S-243. Check the wire from the electrical harness connector terminal 1 to fuse S-243 for open or high resistance.

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 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 Motronic Engine Control Module (ECM) -J220-. Refer to the Repair information.

Using a multimeter, check the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- electrical connector terminal 2 to Motronic Engine Control Module (ECM) -J220- electrical connector T121 terminal 64 for an open circuit.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for a short to voltage, high resistance or 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

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

LEAK DETECTION PUMP, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Leak Detection Pump (LDP) -V144- fuse is OK.
2. The engine must be completely cooled down. IAT must match ECT within 5 Degrees C in order for the LDP to operate. Let sit overnight if possible when testing for voltage to the pump motor.
3. The ignition switched OFF.

Test procedure

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

Start diagnosis

Remove the right rear wheel housing liner. Refer to the Repair information

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

Scheme 41

Checking internal resistance

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

Scheme 42

If any of the specifications are Not obtained

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

If the specified value was obtained

Checking voltage supply

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

Using a multimeter, check the Leak Detection Pump (LDP) --V144-- electrical harness connector terminal 3 for voltage. Connect the negative multimeter lead to engine ground.

Scheme 43

Start the engine.

Specified value: Battery voltage.

Switch the ignition OFF.

If the specified value was Not obtained

Remove fuse S-243. Using a multimeter, check the Leak Detection Pump (LDP) --V144-- wiring from terminal 3 to fuse S-243.

Specified value: 1.5 ohms max

If the specified value was Not obtained

Check the wiring for high resistance 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 or 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) -J220-. Refer to the Repair information.

Using a multimeter, check the Leak Detection Pump (LDP) --V144-- electrical connector terminal 1 to Motronic Engine Control Module (ECM) -J220- electrical connector T121 terminal 80 for an open circuit or high resistance.

Using a multimeter, check the Leak Detection Pump (LDP) --V144-- electrical connector terminal 2 to Motronic Engine Control Module (ECM) -J220- electrical connector T121 terminal 25 for an open circuit or high resistance.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for high resistance, 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) -J220-. Refer to the Repair information.

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

Install the right rear wheel housing liner. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

THROTTLE POSITION SENSOR/ACCELERATOR PEDAL POSITION SENSOR 2, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram

Test requirement

1. The Motronic Engine Control Module (ECM) - J220- 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 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 Repair information

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

Scheme 44

Checking voltage supply and wiring

Switch the ignition ON.

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

Scheme 45

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) -J220-. Refer to the Repair 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) -J220- electrical connector T121 for an open circuit.

Scheme 46

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for a short circuit to each other, Battery (+) or Ground or high resistance.

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

If necessary, repair the faulty wiring connection.

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

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

If no fault is detected in the wiring and the voltage supply was Not OK

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair information.

Install the drivers side storage compartment.

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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

THROTTLE VALVE CONTROL MODULE, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) - J220- 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 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) -J220- based on input from 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

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 47

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 48

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

If the specified value was Not obtained

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

If the specified value was obtained

Check the voltage supply of the Throttle Valve Control Module -J338- from the Motronic Engine Control Module (ECM) -J220- as instructed below.

Checking voltage supply and wiring

Switch the ignition ON.

Using a multimeter, check the Throttle Valve Control Module -J338- electrical harness connector, terminals 2 to 6 for voltage from the ECM.

Scheme 49

Specified value: at least 4.5 V

Switch the ignition OFF.

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) -J220-. Refer to the Repair information.

Using a multimeter, check the Throttle Valve Control Module -J338- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 terminals for an open circuit according to the wiring diagram.

Scheme 50

Specified value: 1.5 ohms max.

If the specified value was Not obtained

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

If necessary, repair the faulty wiring connection.

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

If no fault is detected in the wiring and the voltage supply was Not OK

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

OXYGEN SENSOR BEFORE CATALYTIC CONVERTER, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Heated Oxygen Sensor (HO2S) -G39- fuse OK.
2. The Oxygen Sensor (O2S) Heater -Z19- before catalytic converter 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 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

Perform the function test in Diagnostic Mode 06.

If specified values are obtained

Check for possible intermittent connection or rub through of harness.

Erase the code. Drive the vehicle and generate the readiness code.

If the specified value was Not obtained

Checking primary voltage

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

Scheme 51

Using a multimeter, connect the negative lead to engine ground. Start the engine, and check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminals 2, 3, 4 and 6 for voltage.

Scheme 52

Specified value: 2.40 V - 4.99 V

Switch the ignition OFF.

If the specified value was obtained

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

If the specified value was Not obtained

Checking wiring

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

Install the test box.

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

Remove the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair information.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 terminals for an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

Check the wiring for an open, high resistance, short circuit to each other, 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 found in the wiring and the voltage was Not OK

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

OXYGEN SENSOR BEFORE CATALYTIC CONVERTER, CHECKING HEATER

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Heated Oxygen Sensor (HO2S) -G39- fuse S-243 is 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 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 Repair information.

Checking internal resistance

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

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

Specified value: 2.5 to 19.0 ohms (at approx. 20 °C)

If the specified value was Not obtained

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

If the specified value was obtained

Checking voltage supply

Start the engine.

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

Turn the ignition switch OFF.

Specified value: Battery voltage.

If the specified value was Not obtained

Check the wiring for an open, high resistance or short to Ground and replace any open fuse.

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

If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking Ground 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 Motronic Engine Control Module (ECM) -J220-. Refer to the Repair information.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminal 3 to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 terminal 5 for an open circuit.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for an open, high resistance, short circuit to each other, 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 and the voltage supply was OK

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair informatiion.

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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

OXYGEN SENSOR IN CENTER CATALYTIC CONVERTER CHECKING, BPR ENGINE ONLY

Note. This diagnostic only applies to the California Emissions BPR engine using 3 HO2S sensors. Use only gold-plated terminals when servicing terminals in the electrical harness connectors of the Oxygen Sensor (O2S) 2 in center Three Way Catalytic Converter (TWC) -G465-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse S-243 is OK.
2. Engine Control Module (ECM) -J220- 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 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

Perform the function test in Diagnostic Mode 06.

If specified values are obtained

Check for possible intermittent connection or rub through of harness.

Erase the code. Drive the vehicle and generate the readiness code.

If the specified values are not obtained

Checking primary voltage

Remove the black plastic cover (right side) underneath the vehicle to access the O2S connector. -arrows-.

Disconnect the Oxygen Sensor (O2S) 2 in center Three Way Catalytic Converter (TWC) -G465- electrical harness connector.

Switch the ignition ON.

Using a multimeter, check the Oxygen Sensor (O2S) 2 in center Three Way Catalytic Converter (TWC) -G465- electrical harness connector terminals 3 to 4 for voltage.

Specified value: 0.400 to 0.500 Volts

Switch the ignition OFF.

If the specified value was obtained

Replace the Oxygen Sensor (O2S) 2 in center Three Way Catalytic Converter (TWC) -G465-.

If the specified value was Not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J220-. Refer to the Repair information.

Using a multimeter, check the Oxygen Sensor (O2S) 2 in Center Three Way Catalytic Converter (TWC) -G465- electrical harness connector terminals to the Engine Control Module (ECM) -J220- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

Check the wiring for an open, high resistance, short circuit to each other, 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 and the voltage supply was Not OK

Replace the Engine Control Module (ECM) -J220-. Refer to the Repair information.

Install the right side vehicle O2S connector cover.

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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) ..
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

OXYGEN SENSOR IN CENTER CATALYTIC CONVERTER, CHECKING HEATER

Note. When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S) -G465-, use only gold-plated terminals.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Heated Oxygen Sensor (HO2S) -G465- fuse 15 in Fuse box B is 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 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 black plastic cover (right side) underneath the vehicle to access the O2S connector. -arrows-.

Disconnect the Heated Oxygen Sensor (HO2S) -G465- electrical harness connector.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G465- terminals 1 and 2 for correct resistance.

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

If the specified value was Not obtained

Replace the Heated Oxygen Sensor (HO2S) -G465-.

If the specified value was obtained

Checking voltage supply

Start the engine.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G465- electrical harness connector terminal 1 to engine ground for voltage.

Turn the ignition switch OFF

Specified value: Battery voltage.

If the specified value was Not obtained

Check the wiring for an open, high resistance or short to Ground and replace any open fuse.

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

If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking Ground 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 Motronic Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G465- electrical harness connector terminal to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 for an open circuit.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for an open or high resistance.

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

If necessary, repair the faulty wiring connection.

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

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Install the right side vehicle O2S connector cover.

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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

OXYGEN SENSOR AFTER CATALYTIC CONVERTER, CHECKING

Note. Use only gold-plated terminals when servicing terminals in the electrical harness connectors of the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G130-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB4- OK.
2. Engine Control Module (ECM) -J220- 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 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

Perform the function test in Diagnostic Mode 06.

If specified values are obtained

Check for possible intermittent connection or rub through of harness.

Erase the code. Drive the vehicle and generate the readiness code.

If the specified value was Not obtained

Remove the black plastic cover (right side) underneath the vehicle to access the O2S connector.

Checking primary voltage

Disconnect the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G130- electrical harness connector.

Switch the ignition ON.

Using a multimeter, check the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G130- electrical harness connector terminals 3 to 4 for voltage.

Specified value: 0.400 to 0.500 Volts

Switch the ignition OFF.

If the specified value was obtained

Replace the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G130-..

If the specified value was Not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Using a multimeter, check the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G130- electrical harness connector terminals to the Engine Control Module (ECM) -J220- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

Check the wiring for an open, high resistance, short circuit to each other, 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 and the voltage supply was Not OK

Replace the Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Install the right side vehicle O2S connector cover.

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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

OXYGEN SENSOR AFTER CATALYTIC CONVERTER, CHECKING HEATER

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- fuse 15 in Fuse box B is 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 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 black plastic cover (right side) underneath the vehicle to access the O2S connector..

Checking internal resistance

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

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

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

If the specified value was Not obtained

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

If the specified value was obtained

Checking voltage supply

Turn the ignition switch ON

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

Specified value: Battery voltage.

If the specified value was Not obtained

Check the wiring for an open, high resistance, short circuit to each other, or Ground.

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

If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking Ground 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 Motronic Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Using a multimeter, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- electrical harness connector terminal 2 to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 terminal 6 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 or high resistance.

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

If necessary, repair the faulty wiring connection.

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

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Install the right side vehicle O2S connector cover.

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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

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. Fuse -SB44- OK.
2. The Fuel Primer Relay -J643- 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 connections between engine/transmission/chassis OK.
8. Coolant Temperature at least 80° C.
9. 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

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-.

If specified value was not obtained

Checking voltage supply

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

Start the engine and let it run at idle.

Using a multimeter, check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminal 2 to Ground.

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 2 to the Fuel Pump Relay -J17- socket 23/87 for an open circuit or short to Ground. NOTE: Fuse S-243 is also part of this circuit and may be open if circuit is shorted. refer to Wiring Diagram for circuit details.

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

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring and the voltage supply is 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) -J220-. Refer to the Repair Information.

Using a multimeter, check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms max.

If the specification was not obtained

Check the wiring for a short circuit to each other, Battery (+) 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 and the voltage supply was OK

Replace Mass Air Flow (MAF) Sensor -G70-. Refer to Fuel & Ignition System; Grp 24

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

MANIFOLD ABSOLUTE PRESSURE SENSOR, CHECKING

Note. Use only gold-plated terminals when servicing terminals in harness connector of Manifold Absolute Pressure (MAP) Sensor -G71-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test conditions

1. TheEngine Control Module (ECM) -J220- OK.
2. The parking brake must be applied, otherwise daytime running lights are switched on.
3. On vehicles with automatic transmission, selector lever must be in position "P" or "N".
4. The Ground connections between engine and body must be OK.

Function test

Connect the scan tool.

Start engine and let it run at idle.

Using the scan tool, Check the specified value of the Manifold Absolute Pressure (MAP) Sensor -G71- at idle

If the specified value was obtained

Condition is not present at this time. Check connections for loose or damaged terminals and check harness for an intermittent short.

Erase the DTC. Generate readiness code. Refer to READINESS CODE .

If the specified value was Not obtained

Test sequence

Disconnect the Manifold Absolute Pressure (MAP) Sensor -G71- electrical harness connector.

Start the engine and run at idle speed.

Using a multimeter, check the Manifold Absolute Pressure (MAP) Sensor -G71- electrical harness connector terminals 1 to 3 for voltage.

Specification: Near 5 V

Switch the ignition OFF.

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 Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Using a multimeter, check the Manifold Absolute Pressure (MAP) Sensor -G71- electrical harness connector terminal to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 for resistance.

Specified Value: 1.5 ohm max.

If the specified value was Not obtained

Check the wiring for an open circuit, high resistance, short circuit to each other, 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 and the voltage supply was OK

Replace Manifold Absolute Pressure (MAP) Sensor -G71-.

If the specified voltage supply was Not obtained

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

Install the test box. Refer to the Repair Information.

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

Remove the Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Using a multimeter, check the Manifold Absolute Pressure (MAP) Sensor -G71- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for an open circuit, high resistance, short circuit to each other, 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 and if the voltage supply was Not OK

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

ENGINE COOLANT TEMPERATURE SENSOR 1, CHECKING

Note. The ECT (G62) Sensor 1 and ECT Gauge sensor are combined into a single unit. The unit is mounted in the thermostat housing and has a 4 wire connector. Use only gold-plated terminals when servicing terminals in the electrical harness connector of Engine Coolant Temperature (ECT) Sensor -G62 -.

Special tools and workshop equipment required

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

Test requirements

1. The Motronic Engine Control Module (ECM) - J220- 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 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

Connect the scan tool.

Switch the ignition ON.

Using the scan tool, check the coolant temperature

If the specified value was 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.

Turn the ignition switch OFF.

If the engine shows problems in certain temperature ranges, if the temperature does not climb uniformly or the temperature signal is intermittent.

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

Checking internal resistance

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

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

Use the chart below for the specified values

If the specified value from the chart was Not obtained

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

COOLING FAN CONTROL CIRCUIT, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Test lamp
3. Wiring diagram.

Test requirements

1. The Cooling Fan Module fuse S5 is OK.
2. Battery voltage at least 12.5 V.
3. All electrical consumers switched off.
4. A/C switched off.
5. The ignition switched OFF.

Test procedure

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

Start diagnosis

Disconnect the Cooling Fan Control Module -- electrical harness connector.

Checking voltage supply

Switch the ignition ON.

Using a multimeter, check the Cooling Fan Control Module -- harness connector terminal 1 to ground for voltage.

Using a multimeter, check the Cooling Fan Control Module -- harness connector terminal 2 to ground for voltage.

Specified value for both terminals: Battery voltage.

Switch the ignition OFF.

If the specified value was Not obtained

Check the wiring from the Cooling Fan Control Module -- harness connector terminal 1 to fuse S-163 or terminal 2 to fuse S-5 for high resistance, a short circuit to Ground, or an open circuit. Refer to the Wiring Diagram.

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

If necessary, repair the wiring connection and replace any blown fuse.

If the specified value was obtained

Connect a test lamp to Battery positive. Connect the other end to terminal 4 of the Cooling Fan Control Module -- harness connector.

Specified value: Test lamp is ON.

If the specified value was Not obtained

Check the wiring for an open or high resistance.

Check the harness connector 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) -J220-. Refer to the Repair Information.

Using a multimeter, check the Cooling Fan Control Module --N112-- harness connector terminal 3 to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 for high resistance or an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

Check the 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) -J220-. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

INTAKE AIR TEMPERATURE SENSOR, CHECKING

Note. The Mass Air Flow sensor and the Intake Air Temperature sensor are combined as a unit. Use only gold-plated terminals when servicing terminals in the electrical harness connector of the MAF / IAT sensor -G70 / G42-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test procedure

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

Start diagnosis

Connect the scan tool.

Engine must be at Room Temperature.

Switch the ignition ON.

Using the scan tool, check the intake air temperature

If the specified value was obtained

Fault is intermittent. Check for proper connection, damaged wiring or loose terminals.

Switch the ignition OFF.

If the specified value was Not obtained

Checking internal resistance

Disconnect the MAF / IAT sensor -G70 / G42- electrical harness connector.

Using a multimeter, check the MAF / IAT sensor -G70 / G42- terminals 1 to 2 for resistance.

Use the chart below for the specified values

Specified values

If the specified value in the chart was Not obtained

Replace the MAF / IAT sensor -G70 / G42-.

If the specified value was obtained

Continue the test according to the following table

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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

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) - J220- 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 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 stall.

Test procedure

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

Start diagnosis

Connect the scan tool.

Start the engine.

Using the scan tool, check the engine speed

Switch ignition OFF.

If the specified value was Not obtained

Checking internal resistance

Note. Polarity of the Multimeter leads MUST be followed or the result will be in error leading to misdiagnosis.

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

Using a multimeter, connect the RED multimeter lead to Engine Speed (RPM) Sensor -G28- terminal 1 and the BLACK multimeter lead to terminal 2 for resistance.

Specified value: 13.7 M ohms

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

Using a multimeter, connect the RED multimeter lead to Engine Speed (RPM) Sensor -G28- terminal 1 and the BLACK multimeter lead to terminal 3 for resistance.

Specified value: 13.7 M ohms

If any of the specified values are not obtained

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

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) -J220-. Refer to the Repair Information.

Using a multimeter, check the Engine Speed (RPM) Sensor -G28- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 terminals for an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was 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 no malfunction is detected in the wiring

Remove the Engine Speed (RPM) Sensor -G28- and check the sensor wheel for proper seating, damage and runout Refer to the Repair Information.

If the sensor wheel is OK

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

FUEL INJECTORS, CHECKING

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

Special tools and workshop equipment required

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

Test requirements

1. The Fuel Injector -- fuse is OK.
2. The Engine Speed (RPM) Sensor -G28- 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 connections between engine/transmission/chassis OK.
8. Ignition switched OFF.

Observe safety precautions.

Observe rules for cleanliness.

Test procedure

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

Start diagnosis

Remove the engine cover. Refer to the Repair Information.

Disconnect the Fuel Injector -- electrical harness connectors from Fuel Injectors -N30, N31, N32, N33, N83-.

Checking internal resistance

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

Specified value: 10.0 to 18.5 ohms (at approx. 20 °C)

If the specified value was Not obtained

Replace the malfunctioning Fuel Injector -- Refer to the Repair Information.

If the specified value was obtained

Checking activation and wiring

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

Operate the starter and test the activation of the Fuel Injector -- while engine is cranking.

LED should flicker.

Switch the ignition OFF.

If LED does not flicker

Remove the Fuel Pump Relay -J17-.

Connect a jumper between the Fuel pump relay terminals 30 and 87

Turn the ignition switch ON.

Using a test lamp connected to ground, check terminal 1 of the Fuel Injector -- to be tested. The lamp should be ON.

If the test lamp did not turn on, locate the open or high resistance in the voltage supply circuit. Fuse S-229 is located between the fuel pump relay and the injectors.

If the voltage supply was OK

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) -J220-. Refer to the Repair Information.

Using a multimeter, check the Fuel Injector -- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T60 terminals for an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring.

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

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Install the engine cover. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

ECM VOLTAGE SUPPLY, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) - J220- 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 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-.

Checking voltage

Switch the ignition ON.

Using a multimeter, check the Motronic Engine Control Module (ECM) Power Supply Relay Box socket 2 (relay terminal 30) to Ground.

Specified value: Battery voltage.

Switch the ignition OFF.

If the specified value was Not obtained

Check the wiring connections from the Load Reduction Relay J59 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 2 for an open or a short circuit. Note: Fuse S-237 is between the J59 Load Reduction relay and the J271 ECM relay. Check for an open S-237 fuse. If open, check for a short to ground between the fuse and ECM J271 relay.

Check the wiring for open or short and connections for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring or connection.

If the specified value was obtained

Switch the ignition ON.

Using a multimeter, check the Motronic Engine Control Module (ECM) Power Supply Relay Box -- socket 3, (relay terminal 86) to Ground.

Switch the ignition OFF.

Specified value: Battery voltage.

If the specified value was Not obtained

Check the wiring connections from the Load Reduction Relay J59 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 4 for an open or a short circuit. Note: Fuse S-237 is between the J59 Load Reduction relay and the J271 ECM relay. Check for an open S-237 fuse. If open, check for a short to ground between the fuse and ECM J271 relay.

Check the wiring for open or short and connections for damage, corrosion, loose or broken terminals.

If necessary, repair the faulty wiring or connection.

Repair as necessary.

If the specified value was obtained

Checking activation

Remove the Motronic Engine Control Module (ECM) Power Supply Relay -J271-.

Using a diode test lamp (12 V) connected to Battery +, check the Motronic Engine Control Module (ECM) Power Supply Relay Box -- socket 1 (relay terminal 85) while cranking the engine.

The test lamp should be ON.

Switch the ignition OFF.

If the test lamp was ON

Replace the Motronic Engine Control Module (ECM) Power Supply Relay -J271

If the test lamp was not ON

Using a multimeter, check the Motronic Engine Control Module (ECM) Power Supply Relay -- socket 1 (relay terminal 85), to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 terminal 23 for resistance.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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 ground was not present from the ECM during crank

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

CATALYTIC CONVERTER, CHECKING

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 .

Switch the ignition OFF.

Specified value - Test Passed

If the specified value was Not obtained

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 specified value was obtained

Generate readiness code. Refer to READINESS CODE .

If the DTC returns and no leaks are found in the exhaust system

Replace the catalytic converter with front exhaust pipe. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

SECONDARY AIR INJECTION COMBINATION VALVE, CHECKING

The following procedure is used to test all combination valves.

Special tools and workshop equipment required

1. Hand vacuum pump.

Test conditions

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

Test procedure

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

Start procedure

Remove the vacuum hose from the Secondary Air Injection Combination Valve --.

Connect hand vacuum pump to combination valve vacuum connection.

Remove the air duct hose from the Throttle Valve Control Module -J338- and position aside.

Disconnect the Secondary Air Injection hose.

Inject a light air pressure into the in Secondary Air Injection hose to close the combination valve. (do not use compressed air).

The Secondary Air Injection Combination Valve -- should close and seal. Air should not be able to pass through the valve.

Operate the hand vacuum pump.

The Secondary Air Injection Combination Valve -- should open. Air should be able to pass through the valve.

If combination valve does not open

Replace theSecondary Air Injection Combination Valve

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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

SECONDARY AIR INJECTION PUMP MOTOR, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Secondary Air Injection (SAI) Pump Relay --J299-- fuse is OK.
2. The Motronic Engine Control Module (ECM) Power Supply Relay -J271- fuse OK.
3. Battery voltage at least 12.5 V.
4. All electrical consumers switched off (radiator fan must NOT run during test).
5. A/C switched off.
6. The ignition switched OFF.

Test procedure

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

Start diagnosis

Disconnect theSecondary Air Injection (SAI) Pump Motor --V101-- electrical harness connector.

Note. The Secondary Air Injection system ONLY operates at initial startup when the coolant temperature is near ambient temperature. The pump will operate for approximately 20 to 45 seconds and will NOT run again unless coolant temperature and ambient temperature are within 3 °C of each other.

Checking voltage

Connect a multimeter to theSecondary Air Injection (SAI) Pump Motor --V101-- electrical harness connector terminals 1 to 2.

Start the engine and read the voltage on the multimeter.

Switch the ignition OFF.

Specified value: Battery voltage.

If the specified value was obtained

Replace Secondary Air Injection (SAI) Pump Motor --V101--.

If the specified value was Not obtained

Using a multimeter, check the Secondary Air Injection (SAI) Pump Motor --V101-- electrical harness connector terminal 1 to Ground.

Specified value: 0.5 ohms or less.

If the specified value was Not obtained

Check the ground circuit for an open or high resistance. Refer to Wiring Diagrams.

Repair the circuit as necessary.

If the specified value was obtained

Using a multimeter, check the Secondary Air Injection (SAI) Pump Motor --V101-- electrical harness connector terminal 2 to the Secondary Air Injection (SAI) Pump Relay --J299-- connector terminal 2 (relay 87).

Specified value: 0.5 ohms or less.

If the specified value was Not obtained

Check the voltage supply circuit between the Secondary Air Injection (SAI) Pump Relay --J299-- and the Secondary Air Injection (SAI) Pump Motor --V101-- for an open or high resistance. Refer to Wiring Information.

Repair the circuit as necessary.

If the specified value was obtained

Perform the Secondary Air Injection Pump Relay test to find cause of no voltage to the SAI pump motor.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

SECONDARY AIR INJECTION PUMP RELAY, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.
3. LED Test Lamp

Test requirements

1. Secondary Air Injection (SAI) Pump Relay --J299-- fuse OK.
2. Motronic Engine Control Module (ECM) Power Supply Relay -J271- fuse OK.
3. Battery voltage at least 12.5 V.
4. All electrical consumers switched off.
5. A/C switched off.
6. The ignition switched OFF.

Test procedure

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

Start diagnosis

Note. The Secondary Air Injection system ONLY operates at initial startup when the coolant temperature is near ambient temperature. The pump will operate for approximately 20 to 45 seconds and will NOT run again unless coolant temperature and ambient temperature are within 3 °C of each other.

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

Checking voltage

Using a multimeter, check the Secondary Air Injection (SAI) Pump Relay --J299-- socket 1 (relay 30) to Ground.

Specified value: Battery voltage.

If the specified value was Not obtained

Check the wiring connection from the Secondary Air Injection (SAI) Pump Relay --J299-- socket 1 (relay 30) to the Battery Positive terminal for an open circuit or high resistance.

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

If necessary, repair the faulty wiring connection.

If the specified value was obtained

Install a jumper between relay connector terminal 1 (relay 30) and 2 (relay 87).

The Secondary Air Injection (SAI) Pump Motor --V101-- should turn ON.

If the motor did Not operate

Perform the Secondary Air Injection Pump Motor test.

If the motor did operate

Turn the Ignition switch ON.

Connect an LED test lamp to battery ground.

Connect the other end to relay connector terminal 4 (relay 85).

Turn the Ignition switch OFF.

If the LED did Not turn ON

Locate the open, short or high resistance on the voltage supply circuit from the ECM relay, through fuse S130 to the Secondary Air Injection (SAI) Pump Relay --J299-- terminal 4 (relay 85).

Repair the circuit as necessary.

If the LED did turn ON

Note. The Secondary Air Injection system ONLY operates at initial startup when the coolant temperature is near ambient temperature. The pump will operate for approximately 20 to 45 seconds and will NOT run again unless coolant temperature and ambient temperature are within 3 °C of each other.

Connect an LED test lamp to Battery Positive.

Connect the other end to relay connector terminal 3 (relay 86).

Start the engine.

If the LED was ON

Replace the Secondary Air Injection (SAI) Pump Relay --J299--.

If the LED was Not ON

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) -J220-. Refer to the Repair Information.

Using a multimeter, check the Secondary Air Injection (SAI) Pump Relay --J299-- electrical harness connector terminal 3 (relay 86) to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 terminal 46 for an open circuit or high resistance.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring or connection.

If no malfunction is detected in the wiring

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

SECONDARY AIR INJECTION SOLENOID VALVE, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Secondary Air Injection (SAI) Solenoid Valve --N112-- fuse OK.
2. The Motronic Engine Control Module (ECM) Power Supply Relay -J271- fuse OK.
3. Battery voltage at least 12.5 V.
4. All electrical consumers switched off (radiator fan must NOT run during test).
5. A/C switched off.
6. The ignition switched OFF.

Test procedure

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

Start diagnosis

Note. Voltage is supplied to the Secondary Air Injection (SAI) Solenoid Valve --N112-- from the Motronic Engine Control Module (ECM) Power Supply Relay -J271-.

Procedure

Disconnect the Secondary Air Injection (SAI) Solenoid Valve --N112-- electrical harness connector.

Checking internal resistance

Using a multimeter, check the Secondary Air Injection (SAI) Solenoid Valve --N112-- terminals 1 to 2 for resistance.

Specified value: 3.5 - 8.5ohms (at approx. 20 °C)

If the specified value was Not obtained

Replace the Secondary Air Injection (SAI) Solenoid Valve --N112--.

If the specified value was obtained

Checking voltage supply

Switch the ignition ON.

Using a multimeter, check the Secondary Air Injection (SAI) Solenoid Valve --N112-- electrical connector terminal 1 to ground for voltage.

Specified value: Battery voltage.

Switch the ignition OFF.

If the specified value was Not obtained

Check the wiring from the Secondary Air Injection (SAI) Solenoid Valve --N112-- electrical connector terminal 1 through Fuse S130 to theMotronic Engine Control Module (ECM) Power Supply Relay -J271- for a short circuit to Ground, or an open circuit.

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

If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

Checking wiring

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

Install the test box.

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

Remove the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Using a multimeter --, check the Secondary Air Injection (SAI) Solenoid Valve --N112-- electrical harness connector terminal 2 to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 for an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was 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 no malfunction is detected in the wiring

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

SECONDARY AIR INJECTION SENSOR 1, CHECKING

Special tools and workshop equipment required

1. Multimeter
2. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) - J220- fuses OK.
2. The fuel filter OK.
3. The battery voltage at least 12.5 V.
4. All electrical consumers switched off (radiator fan must NOT run during test).
5. A/C switched off.
6. The fuel tank at least 1 / 4 filled.
7. The ignition switched OFF.

Test procedure

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

Start diagnosis

Remove the engine cover with air filter. Refer to the Repair Information.

Checking voltage

Disconnect the Secondary Air Injection Sensor 1 -G609- electrical harness connector.

Switch the ignition ON.

Using a multimeter, check the Secondary Air Injection Sensor 1 -G609- electrical harness connector for voltage using the chart below.

Switch the ignition off.

If the specified value was obtained

Replace the Secondary Air Injection Sensor 1 -G609-.

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) -J220-. Refer to the Repair Information.

Using a multimeter, check the Secondary Air Injection Sensor 1 -G609- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J220- electrical harness connector T121 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 or short to 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) -J220-. Refer to the Repair Information.

Install the engine cover with air filter. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

CAMSHAFT POSITION SENSOR, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) - J220- 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 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. Refer to the Repair Information.

Disconnect the Camshaft Position Sensor electrical harness connector.

Switch the ignition ON.

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

Specified value: near 5.0 V

Switch the ignition OFF.

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) -J220-. Refer to the Repair Information.

Using a multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector to the Motronic Engine Control Module (ECM) electrical harness connector T121 for an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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-.

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

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Install the engine cover. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code «READINESS CODE»(ref-492781-S33819495672012080600000) .

KNOCK SENSOR, CHECKING

The following procedure is used to diagnose all Knock Sensors --.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The mounting bolt of Knock Sensor (KS) 1 -G61- /Knock Sensor (KS) 2 -G66- tightened to 20 Nm.
2. The Motronic Engine Control Module (ECM) - J220- 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 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. Refer to the Repair Information.

Note. Before disconnecting the Knock Sensor electrical harness connectors, mark the connectors if the same color connectors are used.

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

Checking internal resistance

Note. Correct ohm meter polarity MUST be followed or the results will be in error

Using a multimeter, check the Knock Sensor terminals 1 to 2 for resistance.

Specified value: near 4.85 M ohms

Using a multimeter, check the Knock Sensor terminals 1 to 3 for resistance.

Specified value: OL or no continuity

If any of the specified values were Not obtained

Replace the faulty Knock Sensor (KS) 1 -G61- /Knock Sensor (KS) 2 -G66-.

If the specified values were 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) -J220-. Refer to the Repair Information.

Using a multimeter, Check the Knock Sensor electrical harness connector to the Motronic Engine Control Module (ECM)J220 electrical harness connector T121 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, high resistance, short circuit to Battery (+) or Ground.

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 OK

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Install the engine cover with air filter. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

IGNITION COIL WITH POWER OUTPUT STAGE, CHECKING

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

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, N323- 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 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. Refer to the Repair Information.

Remove the Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323- electrical harness screws.

Disconnect the ignition coil electrical harness connectors from the Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323-.

Checking ground supply

Using a test lamp connected to Battery Positive, check terminals 2 and 4 of the Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323-. The test lamp should be ON for each terminal check.

If the test lamp was Not ON during a terminal check

Check the circuit for an open or high resistance.

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

If necessary, repair the faulty wiring or connection.

If the test lamp was ON

Checking voltage supply

Switch the ignition ON.

Using a multimeter, check the Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323- electrical harness connector terminal 1 to ground for voltage.

Specified value: Battery voltage.

Switch the ignition OFF.

If the specified value was Not obtained

Check the Ignition Coil electrical harness connector terminal 1 through fuse S130 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271 - for an open circuit.

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

If necessary, repair the faulty wiring connection and replace fuse if blown.

If the specified value was obtained

Checking activation

Disable the power supply to theFuel Injectors -N30, N31, N32, N33, N83- by removing Fuse S229.

Using a diode test lamp connected to ground, check the Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323- electrical harness connector terminal 3 of each coil.

Operate the starter.

The LED should blink.

Switch the ignition OFF.

If the LED blinked and the voltage was OK

Replace the faulty Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323- Refer to the Repair Information.

If the LED did Not blink

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) -J220-. Refer to the Repair Information.

Using a multimeter, Check the Ignition Coil electrical harness connector to the Motronic Engine Control Module (ECM)J220 electrical harness connector T121 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, short circuit to Battery (+) or Ground.

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

If necessary, repair the faulty wiring connection.

If the wiring was OK and the LED did not blink

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Connect theIgnition Coils with Power Output Stage -N70, N127, N291, N292, N323- electrical harness connectors to the Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323-.

Install the Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323- electrical harness screws.

Install the engine cover. Refer to the Repair 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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .

CAN BUS TERMINAL RESISTANCE, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirement

1. A CAN-Bus malfunction was recognized.
2. The Engine Control Module (ECM) - J220- 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 connections between engine/transmission/chassis OK.
8. Ignition switched OFF.

Function

The Engine Control Module (ECM) -J220- 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 Engine Control Module (ECM) -J220- 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 Engine Control Module (ECM) -J220-.

Test Procedure

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

Note. The Engine Control Module (ECM) -J220- must remain connected for the following test.

Remove the air cleaner assembly.

Disconnect the ABS Control Module -J104- electrical harness connector.

Using a multimeter, check the ABS Control Module -J104- electrical harness connector terminals 11 to 15 for the correct Terminal Resistance.

Specified value: 57 to 62 ohms (at approx. 20 °C)

If the specified value was Not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J220-. Refer to the Repair Information.

Using a multimeter, check the ABS Control Module -J104- electrical harness connector through the Data Bus Diagnostic On Board Interface -J533- in the instrument cluster wiring harness to the Engine Control Module (ECM) -J220- electrical harness connector for short to ground, high resistance or an open circuit. Refer to the Wiring Diagrams for harness details

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

Check the wiring connection for short to ground, high resistance 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 the Terminal Resistance was Not OK

Replace the Engine Control Module (ECM) -J220-. Refer to the Repair Information.

If no malfunction is found in the wiring and the Terminal Resistance was OK

Replace the Data Bus On Board Diagnostic Interface -J533- (a component of the instrument cluster).

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-492781-S30532282102012080600000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-492781-S08177798392012080600000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-492781-S33819495672012080600000) .