3.2L - Generic Scan Tool - Engine Code(s): Cbra: Other Volkswagen Eos I

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 creating negative pressure (vacuum) within the fuel delivery system.

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

Leak diagnosis is activated automatically shortly following a cold 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 contained within 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 in the throttle valve control module.

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 input 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.

EPC is a system containing multiple sensor inputs and 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 appropriate 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 appropriate service information.

IGNITION SYSTEM

For all ignition and glow plug system component locations, removal/installation procedures and torque specifications, refer to the appropriate 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 appropriate 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 manual for correct tool operation.

The readiness code is erased every time the DTC memory is erased or any time the battery is disconnected. If the DTC memory has been erased or the battery is disconnected, a new readiness code must be generated.

Only erase the DTC memory if a DTC has been stored.

General recommendations

Most monitors will complete easier and quicker using a "steady-foot" and "smooth" acceleration during the drive cycle operation, cruise, and acceleration modes.

Operating conditions

For the EVAP monitor test, the coolant temperature and the ambient air temperature must be between 10°C and 35°C with a difference between them no greater than 4°C. The ambient air temperature must not change more than 4° C during the drive cycle procedure (e.g. when driving out of a heated workshop in the winter).

Test requirements

1. Erase the DTC memory.
2. Coolant temperature must be between 80°C and 110°C.
3. The intake air temperature 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.

Monitor ID 113 ($71): Secondary Air Injection (AIR) System (Bank 1)

Connect the scan tool.

Start the engine and let run at idle speed.

Select "Diagnostic Mode 06 - Check Test Results of Components that are not Continuously Monitored ".

Select "Monitor-ID 113 ($71)".

Select the desired "Test-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY to check for stored DTC's or the corresponding diagnostic repair procedure.

Switch the ignition off.

Monitor ID 114 ($72): Secondary Air Injection (AIR) System (Bank 2)

Connect the scan tool.

Start the engine and let run at idle speed.

Select "Diagnostic Mode 06 - Check Test Results of Components that are not Continuously Monitored".

Select "Monitor-ID 114 ($72)".

Select the desired "Test-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY to check for stored DTC's or the corresponding diagnostic repair procedure.

Switch the ignition off.

Monitor-ID 162 ($A2): Misfire Cylinder 1 Data

Connect the scan tool.

Start the engine and let run at idle speed.

Select "Diagnostic Mode 06 - Check Test Results of Components that are not Continuously Monitored ".

Select "Monitor-ID 162 ($A2)".

Select the desired "Test-ID " or "Hex-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY to check for stored DTC's or the corresponding diagnostic repair procedure.

Switch the ignition off.

Monitor-ID 163 ($A3): Misfire Cylinder 2 Data

Connect the scan tool.

Start the engine and let run at idle speed.

Select "Diagnostic Mode 06 - Check Test Results of Components that are not Continuously Monitored".

Select "Monitor-ID 163 ($A3)".

Select the desired "Test-ID ".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY to check for stored DTC's or the corresponding diagnostic repair procedure.

Switch the ignition off.

Monitor-ID 164 ($A4): Misfire Cylinder 3 Data

Connect the scan tool.

Start the engine and let run at idle speed.

Select "Diagnostic Mode 06 - Check Test Results of Components that are not Continuously Monitored ".

Select "Monitor-ID 164 ($A4)".

Select the desired "Test-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY to check for stored DTC's or the corresponding diagnostic repair procedure.

Switch the ignition off.

Monitor-ID 165 ($A5): Misfire Cylinder 4 Data

Connect the scan tool.

Start the engine and let run at idle speed.

Select "Diagnostic Mode 06 - Check Test Results of Components that are not Continuously Monitored ".

Select "Monitor-ID 165 ($A5)".

Select the desired "Test-ID ".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY to check for stored DTC's or the corresponding diagnostic repair procedure.

Switch the ignition off.

Monitor-ID 166 ($A6): Misfire Cylinder 5 Data

Connect the scan tool.

Start the engine and let run at idle speed.

Select "Diagnostic Mode 06 - Check Test Results of Components that are not Continuously Monitored ".

Select "Monitor-ID 166 ($A6)".

Select the desired "Test-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY to check for stored DTC's or the corresponding diagnostic repair procedure.

Switch the ignition off.

Monitor-ID 167 ($A7): Misfire Cylinder 6 Data

Connect the scan tool.

Start the engine and let run at idle speed.

Select "Diagnostic Mode 06 - Check Test Results of Components that are not Continuously Monitored ".

Select "Monitor-ID 167 ($A7)".

Select the desired "Test-ID".

Check specified values at idle.

If any of components or systems fail to meet the specified values. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY to check for stored DTC's or the corresponding diagnostic repair procedure.

Switch the ignition off.

FUEL PUMP CHECKING

Special tools and workshop equipment required

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

Test conditions

1. Battery voltage 12.5 V.
2. Fuse -SB6- OK.
3. Fuel filter OK.
4. Ignition switched off.

Test procedure

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

Start diagnosis

Remove the rear seat bench. Refer to Rear Seats .

Remove cover retainers -arrows- from the right sealing flange.

Scheme 70

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

Scheme 71

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

Connect a jumper cable from an Electrical connector test lead set to terminal -5- of the fuel delivery unit and to vehicle Ground.

Scheme 72

Press switch on the hand held remote control (jumper).

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

Listen for an operating noise from the fuel pump.

If no operating noise is heard

Scheme 73

Using a multimeter, check the electrical circuit between terminals 1 and 5 of the fuel delivery unit for resistance.

Specified value: 03 to 1.5 ohms.

If the specified value was Not obtained, replace the Fuel Delivery Unit.

If the specified value was obtained, check the electrical harness for power and ground supply to the fuel pump. Note that the fuel pump is not supplied continuous power when the engine is not running. Refer to the appropriate SYSTEM WIRING DIAGRAMS 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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

FUEL DELIVERY, 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 (high pressure).
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 Rear Seats .

Remove cover retainers -arrows- from the right sealing flange.

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

Open cover of relay and fuse panel in the engine compartment E-box.

Remove fuse SB-7 from fuse holder

Connect hand held remote control (jumper) to the left terminal (in direction of travel) of fuse socket. -arrow-.

Scheme 74

Using insulating tape, tape over second contact of hand held remote control (jumper) to prevent a short circuit.

Connect alligator clip to vehicle battery B+.

Disconnect return line -1- from fuel pressure regulator.

Scheme 75

Note. Press in securing ring to disengage the fuel line.

Connect adapter hose to fuel pressure regulator and hold end of adapter in a measuring container.

Run hand held remote control (jumper) approximately 5 seconds to fill the fuel filter.

Empty measuring container.

Delivery rate of Fuel Pump is dependent on voltage. Therefore connect multimeter to battery.

Operate remote control for 30 seconds and measure battery voltage.

Compare the quantity of fuel delivered with specification.

Scheme 76

* Minimum delivery rate cm 3 /30 s

** Voltage at fuel pump with engine off and pump running (approx. 2 Volts less than battery voltage).

Example

During test, a voltage of 12.5 volts is measured at the battery. Since the voltage at the pump is approx. 2 Volts less than battery voltage, there is a minimum delivery rate of approx. 580 cm 3 /30 s.

If the minimum delivery rate is not attained

Check the supply line to filter for possible restrictions (kinks) or clogging.

If fuel line is OK.

Check fuel delivery rate in front of fuel filter.

Disconnect the supply line from fuel filter input.

Note. Press in securing ring to disengage the fuel line.

Connect a Fuel pressure test set (high pressure) as shown.

Connect an adapter hose to the Fuel pressure test set (high pressure) and hold it in a measuring container.

Open shut off valve of Fuel pressure test set (high pressure). Lever will point in direction of flow.

Operate hand held remote control (jumper). Slowly close shut off tap, until pressure gauge shows 4 bar. From this point on do not move position of shut off tap.

Empty the measuring container.

Operate hand held remote control (jumper) for 30 seconds. Compare delivery quantity with value determined from the first measurement.

If minimum delivery rate is now obtained

Replace fuel filter.

If minimum delivery rate is again not obtained

Remove fuel delivery unit and check filter strainer for dirt.

If the fuel filter and fuel strainer are OK

Replace fuel delivery unit.

Assembly is performed in reverse order of removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

EVAP SYSTEM, DETECTING LEAKS

Function

The leak detection system recognizes leaks in the complete fuel system, including the fuel tank, EVAP canister and the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-.

On the mechanical side, the leak detection system consists mainly of a vacuum-driven diaphragm pump equipped with a reed contact on the actuation rod of the pump diaphragm. The pump is supplied with vacuum by the engine intake stroke.

1. When leak detection is activated, the diaphragm pump pumps the fuel system up to 20 - 30 mbar. The pump diaphragm is then moved out so that the reed contact at the operating rod remains in the "open" position.
2. During the leak diagnosis, the reed contact is monitored to check if it remains open within 10 seconds. This indicates the system is sealed.
3. If the pressure falls (indicating a leak), the diaphragm moves back and the reed contact closes.
4. If the reed contact closes within 10 seconds of leak detection time, a further test is performed: In this case the diaphragm pump pumps four times again. The Engine Control Module (ECM) -J623- measures the time for each of the four pumps until the reed contact is closed again. From that, the control module can recognize a "small leak" (greater than 1 mm in diameter) or a "large leak".

Leak diagnosis is activated automatically shortly following cold engine start up. If a malfunction is determined, an entry is made to the Diagnostic Trouble Code (DTC) memory. The Malfunction Indicator Lamp (MIL) -K83- in the instrument cluster lights up if the malfunction is recognized for two subsequent drive cycles.

EVAP SYSTEM LEAK CHECKING

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) canister system for leaks.

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

If a leak is detected

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

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

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

Check that the seal under the locking flange is properly tightened on the fuel tank.

Repair or replace any damaged component.

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

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

Perform a road test to verify repair.

If a DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

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

EVAP CANISTER PURGE REGULATOR VALVE CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB38- OK.
2. The ignition switched off.

Note. Voltage for the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- is supplied by the Power Supply Relay (terminal 30, B+) -J317-.

Test procedure

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

Start diagnosis

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

Checking internal resistance

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

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

If the specified value was Not obtained

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

If the specification was obtained

Checking voltage supply

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

Scheme 77

Operate the starter briefly.

Specified value: Battery voltage.

If the specified value was Not obtained

Check the wiring connection from the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- electrical harness connector terminal 1 to the Power Supply Relay (terminal 30, B+) -J317- terminal 87 for an open, high resistance, a short circuit to Battery positive (+) or Ground.

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 Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- electrical connector terminal 2 to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminal 64 for resistance.

Specified value: 1.5 ohms.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, a short circuit to Battery positive or Ground.

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

If necessary, repair the wiring connection.

If the specification was obtained

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

Perform a road test to verify repair.

If the DTC does Not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

LEAK DETECTION PUMP CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB38- OK.
2. The ignition switched off.

Note. Voltage for the Leak Detection Pump (LDP) -V144- is supplied by the Power Supply Relay (terminal 30, B+) -J317-.

Test procedure

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

Start diagnosis

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

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

Scheme 78

Checking internal resistance

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

Scheme 79

If the specifications were Not obtained

Replace the Leak Detection Pump (LDP) --V144--.

If the specified values were obtained

Checking voltage supply

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

Scheme 80

Operate the starter briefly.

Specified value: Battery voltage.

Switch the ignition Off.

If the specified value was Not obtained

Check the wiring connection from the Leak Detection Pump (LDP) --V144-- electrical harness connector terminal 3 to the Power Supply Relay (terminal 30, B+) -J317- terminal 87 for an open circuit, a short circuit to Battery positive or to Ground.

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

If necessary, repair the wiring connection.

If the specified value was obtained

Checking output wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Leak Detection Pump (LDP) -V144- electrical connector terminals to Engine Control Module (ECM) -J623- electrical connector T121 for resistance.

Specified value: 1.5 ohms.

If the specifications were Not obtained

Check the wiring for an open circuit, high resistance, short circuit to Battery positive or Ground.

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

If necessary, repair the wiring connection.

If no malfunction is found in wiring

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

THROTTLE POSITION SENSOR AND ACCELERATOR PEDAL POSITION SENSOR 2 CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram

Test requirement

1. The Engine Control Module (ECM) - J623- fuses OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.

Note. Use only gold-plated terminals when servicing the electrical harness connector terminals in Throttle Position 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

Using a screwdriver, remove the steering column cover -arrows-.

Scheme 81

Disconnect the Throttle Position Sensor -G79-/Accelerator Pedal Position Sensor 2 -G185- electrical harness connector -2-.

Scheme 82

Checking voltage supply

Switch the ignition On.

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

Scheme 83

Switch the ignition Off.

If the specified values were obtained

Replace the Throttle Position Sensor -G79-/Accelerator Pedal Position Sensor 2 -G185-.

If any of the specified values were Not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Throttle Position Sensor -G79-/Accelerator Pedal Position Sensor 2 -G185- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical connector T121 for resistance.

Scheme 84

Specified value: 1.5 ohms max.

If the specification is Not obtained

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

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 supply was OK

Replace the Throttle Position Sensor -G79-/Accelerator Pedal Position Sensor 2 -G185-.

If no malfunction is found in wiring

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

Perform a road test to verify repair.

If the DTC does Not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

OXYGEN SENSOR BANK 1 SENSOR 1 HEATER CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -- -SB11- 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 air filter.

Disconnect the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector -2-.

Scheme 85

Checking internal resistance

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

Scheme 86

Specified value: 1.5 to 10.0 ohms (at approx. 20°C)

If the specification was Not obtained

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

If the specification was obtained

Checking voltage supply

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

Crank the engine.

Specified value: Battery voltage.

Switch the engine Off.

If the specification was Not obtained

Check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminal 4 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 2/87 for an open circuit, 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 the specification was obtained

Checking Ground activation

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 Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness connector T121 for resistance.

Specified value: 1.5 ohms max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 found in the wiring and if the voltage supply was OK

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

Perform a road test to verify repair.

If the DTC does Not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

OXYGEN SENSOR BANK 2 SENSOR 1 HEATER CHECKING

Note. Oxygen Sensor (O2S) 2 Heater -Z28- is part of Heated Oxygen Sensor (HO2S) 2 -G108- and cannot be serviced separately. When servicing terminals in the electrical harness connector of Heated Oxygen Sensor (HO2S) 2 -G108-, use only gold-plated terminals.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -- -SB11- 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 air filter.

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

Checking internal resistance

Using a multimeter, check the Heated Oxygen Sensor (HO2S) 2 -G108- terminals 3 to 4 for resistance.

Specified value: 1.5 to 10.0 ohms (at approx. 20°C)

If the specification was Not obtained

Replace the Heated Oxygen Sensor (HO2S) 2 -G108-.

If the specification was obtained

Checking voltage supply

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

Crank the engine.

Specified value: Battery voltage.

Switch the engine Off.

If the specification was Not obtained

Check the Heated Oxygen Sensor (HO2S) 2 -G108- electrical harness connector terminal 4 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 2/87 for an open circuit, high resistance, 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 the specification 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 Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness connector T121 for resistance.

Specified value: 1.5 ohms max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, a short circuit to each other, Battery (+) and 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 supply was OK

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

OXYGEN SENSOR BANK 1 SENSOR 2 HEATER CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB12- 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 right vehicle floor cover -arrows-.

Scheme 87

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

Scheme 88

Checking internal resistance

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

Scheme 89

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

If the specification was Not obtained

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

If the specification was obtained

Checking voltage supply

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

Crank the engine.

Specified value: Battery voltage.

Switch the engine Off.

If the specification was Not obtained

Check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 2/87 for an open circuit, high resistance, 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 the specification was obtained

Checking Ground activation

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 Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness connector T121 for resistance.

Scheme 90

Specified value: 1.5 ohms max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 found in the wiring and the voltage supply was OK

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

OXYGEN SENSOR BANK 2 SENSOR 2 HEATER CHECKING

Note. Oxygen Sensor (O2S) 2 (behind Three Way Catalytic Converter (TWC)) Heater -Z30- is part of Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- and cannot be serviced separately. Vehicle must be raised before electrical harness connector for the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- is accessible. When servicing terminals in harness connector of Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131-, use only gold-plated terminals.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB12- 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 right vehicle floor cover -arrows-.

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

Checking internal resistance

Using a multimeter, check the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- terminals 1 to 2 for resistance.

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

If the specification was Not obtained

Replace Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131-.

If the specification was obtained

Checking voltage supply

Using a multimeter, check the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- electrical harness connector terminal 1 to ground for voltage.

Crank the engine.

Specified value: Battery voltage.

Switch the engine Off.

If the specification was Not obtained

Check the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 2/87 for an open circuit, high resistance, 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 the specification 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 Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness connector T121 for resistance.

Specified value: 1.5 ohms max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 found in the wiring and the voltage supply was OK

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

MASS AIR FLOW SENSOR/INTAKE AIR TEMPERATURE SENSOR CHECKING

Note. The Intake Air Temperature Sensor G42 is part of the Mass Air Flow Sensor G70 and cannot be replaced separately. 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 -SB10- 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. Coolant Temperature at least 80° C.
8. Ignition switched off.

Test procedure

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

Start diagnosis

Connect the scan tool.

Start engine and let it run at idle.

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

Switch ignition Off.

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

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

If specified value was Not obtained

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

Checking voltage supply

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

Scheme 91

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 engine Ground.

Scheme 92

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 ECM Power Supply Relay -J271- terminal 2/87 for an open circuit, high resistance, a short circuit to each other or Ground.

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

Checking electrical circuit

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms max.

If the specification was Not obtained

Check the wiring for an open circuit, 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 found in the wiring and the voltage supply was OK

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

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

THROTTLE VALVE CONTROL MODULE CHECKING

Note. Use only gold-plated terminals when servicing terminals in harness connector of this system.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Engine Control Module (ECM) - J623- fuses OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground 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 Electronic Power Control (EPC) -G186- in Throttle Valve Control Module - J338-. It is operated by Engine Control Module (ECM) -J623- according to specifications of Throttle Position (TP) Sensor -G79-/Accelerator Pedal Position Sensor 2 -G185 -.

Components of Throttle Valve Control Module -J338

1. Throttle Drive 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

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.

Checking resistance

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

Scheme 93

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

If the specification was Not obtained

Replace the Throttle Valve Control Module - J338-.

If the specification was obtained

Checking voltage supply

Switch the ignition On.

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

Scheme 94

Specified value: at least 4.5 V

Switch the ignition Off.

If the specified value was obtained

Replace the Throttle Valve Control Module - J338-.

If the specified value was Not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Throttle Drive Electronic Power Control (EPC) -G186- at Throttle Valve Control Module -J338- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminals for resistance.

Scheme 95

Specified value: 1.5 ohms max.

If the specification is Not obtained

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

If necessary, repair the faulty wiring connection.

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

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

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

POSITIVE CRANKCASE VENTILATION HEATING ELEMENT CHECKING

Note. Use only gold-plated terminals when servicing terminals in the electrical harness connector of Positive Crankcase Ventilation (PCV) Heating Element -N79-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SA1- OK.
2. Fuse -SA5- OK.
3. Fuse -SC1- OK.
4. Battery voltage at least 12.5 volts.
5. All electrical consumers such as, lights and rear window defroster, switched off.
6. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
7. A/C switched off.
8. Ground connections between engine/transmission/chassis OK.
9. Ignition switched off.
10. Engine cold.

Test procedure

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

Start diagnosis

Disconnect the Positive Crankcase Ventilation (PCV) Heating Element -N79- electrical harness connector.

Using a multimeter, check the Positive Crankcase Ventilation (PCV) Heating Element -N79- terminals 1 to 2 for resistance.

Scheme 96

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

If the specified value was not obtained

Replace the Positive Crankcase Ventilation (PCV) Heating Element -N79-.

If the specified value was obtained

Checking voltage

Switch the ignition On.

Using a multimeter, check the Positive Crankcase Ventilation (PCV) Heating Element -N79- electrical connector terminal 1 to Ground for voltage.

Scheme 97

Specified value: Battery voltage.

Switch the ignition Off.

If the specified value was Not obtained

Check the wiring from the Positive Crankcase Ventilation (PCV) Heating Element -N79- electrical connector terminal 1 to the Battery positive for an open circuit, high resistance, or a short circuit to Ground.

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

If necessary, repair the wiring connection.

If the specified value was obtained

Checking Ground

Using a multimeter, check the Positive Crankcase Ventilation (PCV) Heating Element -N79- electrical connector terminal 2 to Ground for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 the specification was obtained

Replace the Positive Crankcase Ventilation (PCV) Heating Element -N79-.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

ENGINE COOLANT TEMPERATURE SENSOR CHECKING

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

Special tools and workshop equipment required

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

Test requirements

1. The Engine Control Module (ECM) - J623- fuses OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground 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 is not obtained

Continue test according to the following table

If the specified value was obtained

Start the engine and let it run at idle.

The temperature value must increase uniformly in increments of 1.0°C.

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

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

Checking internal resistance

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

Scheme 98

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

Use the chart below for the specified values

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

Specified values

Scheme 99

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

If any of the specified values were Not obtained

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

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

ENGINE COOLANT TEMPERATURE SENSOR ON RADIATOR, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Engine Control Module (ECM) - J623- fuses OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground 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

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

Scheme 100

Checking internal resistance

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

Use the chart below for the specified values

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

Specified values

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

If any of the specified values were Not obtained

Replace the Engine Coolant Temperature (ECT) Sensor (on Radiator) -G83-.

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) -J623-. Refer to the Repair Information.

Using a multimeter, check the Engine Coolant Temperature (ECT) Sensor (on Radiator) -G83- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 the specification was obtained

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

ELECTRIC COOLANT PUMP CHECKING

Note. Use only gold-plated terminals when servicing terminals in the electrical harness connector of Coolant Pump -V50-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Auxiliary Engine Coolant Pump Relay -J496- OK.
2. The Coolant Pump -V50- fuse 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.
9. Engine cold.

Test procedure

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

Start diagnosis

Disconnect the Coolant Pump -V50- electrical harness connector.

Checking voltage

Switch the ignition On.

Using a multimeter, check the Coolant Pump -V50- 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 wiring from the Coolant Pump -V50- electrical connector terminal 1 to the Auxiliary Engine Coolant Pump Relay -J496- socket 2/87 for a short circuit to Ground, 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

Checking Ground

Using a multimeter, check the Coolant Pump -V50- electrical connector terminal 2 to Ground for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

Check the wiring from the Coolant Pump -V50- electrical connector terminal 1 to Ground connection on electronic fan control for or an open circuit, high resistance, a short circuit to Battery (+) or Ground.

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

If necessary, repair the faulty wiring connection.

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

Replace the Auxiliary Engine Coolant Pump Relay -J496-.

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

Replace the Coolant Pump -V50-.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

ENGINE SPEED SENSOR CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Engine Control Module (ECM) - J623- fuses OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.
7. Ignition switched off.

Function

The Engine Speed 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 .

Function test

Connect the scan tool.

Switch the ignition On.

Using the scan tool, check the engine speed

Switch ignition Off.

If the specified value was Not obtained

Start diagnosis

Disconnect the Engine Speed Sensor -G28- electrical harness connector.

Checking internal resistance

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

Scheme 101

Specified value: 700 to 1000 Ohm

Check Engine Speed Sensor -G28- terminals 1 to 2 and 1 to 3 for short circuits.

Specified value: infinity (infinity)

If any of the specified values are Not obtained

Replace the Engine Speed Sensor -G28-.

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 Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Engine Speed Sensor -G28- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

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

Check wiring shield for proper ground.

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

If necessary, repair the faulty wiring connection.

If the specification was obtained

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

If the sensor wheel is OK

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

INTAKE MANIFOLD RUNNER CONTROL VALVE CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB38- OK.
2. The Power Supply Relay (terminal 30, B+) -J317- OK.
3. The parking brake engaged.
4. The battery voltage at least 12.5 V.
5. The selector lever of automatic transmission in position "P" or "N".
6. All electrical consumers switched off (radiator fan must NOT run during test).
7. A/C switched off.
8. The fuel tank at least 1 / 4 filled.
9. The ignition switched off.

Test procedure

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

Start diagnosis

Disconnect the Intake Manifold Runner Control Valve -N316- electrical harness connector.

Checking internal resistance

Using a multimeter, check the Intake Manifold Runner Control Valve -N316- terminals 1 to 2 for resistance

Scheme 102

Specified value: 450 to 1000 ohms.

If the specified value was Not obtained

Replace the Intake Manifold Runner Control Valve -N316-.

If the specified value was obtained

Checking voltage

Crank the engine.

Using a multimeter, check the Intake Manifold Runner Control Valve -N316- 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 wiring from the Intake Manifold Runner Control Valve -N316- electrical harness connector terminal 1 to the Power Supply Relay (terminal 30, B+) -J317- terminal 87 for an open circuit, high resistance, or a short circuit to Ground.

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

If necessary, repair the wiring connection.

If the specified value was obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Intake Manifold Runner Control Valve -N316- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness connector T121 for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 the specification was obtained

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

EXHAUST FLAP VALVE 1 CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB35- OK.
2. The Power Supply Relay (terminal 30, B+) -J317- OK.
3. The parking brake engaged.
4. The battery voltage at least 12.5 V.
5. The selector lever of automatic transmission in position "P" or "N".
6. All electrical consumers switched off (radiator fan must NOT run during test).
7. A/C switched off.
8. The fuel tank at least 1 / 4 filled.
9. The ignition switched off.

Test procedure

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

Start diagnosis

Disconnect the Exhaust Flap Valve 1 -N321- electrical harness connector.

Checking internal resistance

Using a multimeter, check the Exhaust Flap Valve 1 -N321- terminals 1 to 2 for resistance

Specified value: 450 to 1000 ohms.

If the specified value was Not obtained

Replace the Exhaust Flap Valve 1 -N321-.

If the specified value was obtained

Checking voltage

Crank the engine.

Using a multimeter, check the Exhaust Flap Valve 1 -N321- 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 wiring from the Exhaust Flap Valve 1 -N321- electrical harness connector terminal 1 to the Power Supply Relay (terminal 30, B+) -J317- terminal 87 for an open circuit, high resistance, or a short circuit to Ground.

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

If necessary, repair the wiring connection.

If no malfunctions are found in the wiring

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Exhaust Flap Valve 1 -N321- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness connector T121 for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 the specification was obtained

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

FUEL INJECTOR, CHECKING

The following test procedure is used to diagnose Fuel Injectors -N30, N31, N32, N33, N83, N84-.

Special tools and workshop equipment required

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

Test requirements

1. Fuse -SB6- 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.

Observe Safety Precautions.

Observe rules for cleanliness.

Test procedure

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

Start diagnosis

Disconnect the Fuel Injector -- electrical harness connectors from Fuel Injectors -N30, N31, N32, N33, N83, N84-.

Checking internal resistance

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

Scheme 103

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

If the specified value was not obtained

Replace the faulty Fuel Injector --.

If the specified value was obtained

Checking activation and wiring

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

Scheme 104

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

LED should flicker.

Switch the ignition Off.

If LED does not flicker

If the 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 Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Fuel Injector -- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminals for resistance.

Scheme 105

Specified value: 1.5 ohms Max.

If the specification is Not obtained

Check the wiring for an open circuit, high resistance, 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 found in the wiring

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

HEATED OXYGEN SENSOR BANK 1 SENSOR 1 CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -- -SB11- 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

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

Switch ignition off.

If the specified values are Not obtained

Checking primary voltage

Remove the air filter.

Disconnect the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector -2-.

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

Specified value: 0.400 to 0.500 Volts

Switch the ignition Off.

If the specified value was Not obtained

Replace Heated Oxygen Sensor (HO2S) -G39-.

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) -J623-. Refer to the Repair Information.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 the specification was obtained

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

Perform a road test to verify repair.

If the DTC does not return

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

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

HEATED OXYGEN SENSOR BANK 2 SENSOR 1 CHECKING

Note. When servicing terminals in the electrical harness connector of Heated Oxygen Sensor (HO2S) 2 -G108-, use only gold-plated terminals.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -- -SB11- 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

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

Switch ignition Off.

If the specified values are Not obtained

Checking primary voltage

Remove the air filter.

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

Using a multimeter, check the Heated Oxygen Sensor (HO2S) 2 -G108- electrical harness connector -2- terminals 1 to 5 for voltage.

Specified value: 0.400 to 0.500 Volts

Switch the ignition Off.

If the specified value was Not obtained

Replace Heated Oxygen Sensor (HO2S) 2 -G108-.

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) -J623-. Refer to the Repair Information.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) 2 -G108- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 the specification was obtained

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

HEATED OXYGEN SENSOR BANK 1 SENSOR 2 CHECKING

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. Fuse -SB12- 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

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

Switch ignition Off.

If the specified values are Not obtained

Checking primary voltage

Remove the right vehicle floor cover -arrows-.

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

Switch the ignition On.

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

Specified value: 0.400 to 0.500 Volts

Switch the ignition Off.

If the specified value was obtained

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

If the specified value was Not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 the specification was obtained

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

Perform a road test to verify repair.

If the DTC does not return

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

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

HEATED OXYGEN SENSOR BANK 2 SENSOR 2 CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB12- 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

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

Switch ignition Off.

If the specified values are Not obtained

Checking primary voltage

Remove the right vehicle floor cover -arrows-.

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

Switch the ignition On.

Using a multimeter, check the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- 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 Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131-.

If the specified value was Not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a Multimeter, check the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 the specification was obtained

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

ENGINE CONTROL MODULE VOLTAGE SUPPLY, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring Diagram.

Test requirements

1. Fuse -SA1- OK.
2. Fuse -SB23- OK.
3. Fuse -SB28- OK.
4. The Ground connections at the engine and transmission OK.
5. The battery voltage at least 12.5 V.
6. The generator OK.

Test procedure

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

Start diagnosis

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Checking voltage supply

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

Specified value: 12.5 V

If the specified value was Not obtained

Check the Motronic Engine Control Module (ECM) -J623- electrical harness connector T121 terminal 62 to Battery Positive for an open circuit, high resistance, or short to Ground.

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

If necessary, repair the wiring connection.

If the specified value was obtained

Switch the ignition On.

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

Specified value: 12.5 V

Switch the ignition Off.

If the specified value was Not obtained

Check the Motronic Engine Control Module (ECM) -J623- electrical harness connector T121 terminal 3 to the Power Supply Relay (terminal 30, B+) -J317- socket 87 for an open circuit, high resistance, or short to Ground.

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

If necessary, repair the wiring connection.

If the specified value was obtained

Checking Ground

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

Specified value: 1.5 ohms.

If any of the specified values are Not obtained

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

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

If necessary, repair the wiring connection.

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

Perform a road test to verify any electrical repairs.

If the fault does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

ENGINE CONTROL MODULE POWER SUPPLY RELAY CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagrams.

Test requirements

1. The Motronic Engine Control Module (ECM) -J623- fuses OK.
2. Fuse -SA1- OK.
3. Fuse -SA5- OK.
4. The Ground connections at the engine and transmission OK.
5. The battery voltage at least 12.5 V.
6. The generator OK.

Test procedure

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

Start diagnosis

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

Specified value: 12.5 V

If the specified value was Not obtained

Check the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 1/30 to the Battery positive for an open circuit, high resistance, or short to Ground.

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

If necessary, repair the wiring connection.

If the specified value was obtained

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

Specified value: 12.5 V

If the specified value was Not obtained

Check the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 3/86 to Battery positive for an open circuit, high resistance, or short to Ground.

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

If necessary, repair the wiring connection.

If the specified value was obtained

Checking Ground

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

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

Specified value: 1.5 ohms.

If the specified value was Not obtained

Check the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 4/85 to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T121 terminal 65 for an open circuit, high resistance, or a short to Battery (+).

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

If necessary, repair the wiring connection.

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

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

Perform a road test to verify repair.

If the fault does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

POWER SUPPLY RELAY, TERMINAL 30, B+ CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagrams.

Test requirements

1. Fuse -SA1- OK.
2. Fuse -SB23- OK.
3. The Ground connections at the engine and transmission OK.
4. The battery voltage at least 12.5 V.
5. The generator OK.

Test procedure

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

Start diagnosis

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

Specified value: 12.5 V

If the specified value was Not obtained

Check the Power Supply Relay (terminal 30, B+) -J317- socket 30 to the Battery positive for an open circuit, high resistance or short to Ground.

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

If necessary, repair the wiring connection.

If the specified value was obtained

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

Specified value: 12.5 V

If the specified value was Not obtained

Check the Power Supply Relay (terminal 30, B+) -J317- socket 85 to Battery positive for an open circuit, high resistance or short to Ground.

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

If necessary, repair the wiring connection.

If the specified value was obtained

Checking Ground

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

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

Specified value: 1.5 ohms.

If the specified value was Not obtained

Check the Power Supply Relay (terminal 30, B+) -J317- socket 86 to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T121 terminal 23 for an open circuit, high resistance or a short to Battery (+).

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 Power Supply Relay (terminal 30, B+) -J317-.

Perform a road test to verify repair.

If the fault does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

AUXILIARY ENGINE COOLANT PUMP RELAY CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagrams.

Test requirements

1. Fuse -SB15- OK.
2. Fuse -SB29- OK.
3. The Ground connections at the engine and transmission OK.
4. The battery voltage at least 12.5 V.
5. The generator OK.

Test procedure

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

Start diagnosis

Switch the ignition On.

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

Switch the ignition Off.

Specified value: 12.5 V

If the specified value was Not obtained

Check the Auxiliary Engine Coolant (EC) Pump Relay -J496- socket 1/30 to the Power Supply Relay (terminal 30, B+) -J317- socket 87 for an open circuit, high resistance or short to Ground.

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

If necessary, repair the wiring connection.

If the specified value was obtained

Switch the ignition On.

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

Switch the ignition Off.

Specified value: 12.5 V

If the specified value was Not obtained

Check the Auxiliary Engine Coolant (EC) Pump Relay -J496- socket 4/86 to the Power Supply Relay (terminal 30, B+) -J317- socket 87 for an open circuit, high resistance or short to Ground.

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

If necessary, repair the wiring connection.

If the specified value was obtained

Checking Ground

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

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

Specified value: 1.5 ohms.

If the specified value was Not obtained

Check the Auxiliary Engine Coolant (EC) Pump Relay -J496- socket 85 to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T121 terminal 48 for an open circuit, high resistance or a short to Battery (+).

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

If necessary, repair the wiring connection.

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

Replace the Auxiliary Engine Coolant (EC) Pump Relay -J496-.

Perform a road test to verify repair.

If the fault does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

ENGINE CONTROL MODULE REPLACING

Removing

Special tools and workshop equipment required

1. Heat gun.

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

Work procedure

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

Connect the scan tool.

Switch the ignition on.

Using the scan tool, select "Vehicle information".

Select " Calibration Identification" in vehicle information.

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

Record the electronic control module identification number.

End diagnosis and switch the ignition off.

Procedure

Remove windshield wiper arms, plenum chamber cover and plenum chamber facing wall. Refer to the Repair Information.

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

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

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

Repeat the previous steps for the second shear bolt.

Insert a screwdriver -A- between the protective housing and retaining plate -arrow-.

Scheme 106

Pry the protective housing upward using screwdriver -A- and pull it off sideways from retaining plate -arrow-.

Scheme 107

Disconnect the forward electrical harness connector -1- from Engine Control Module (ECM).

Pry up locking mechanism -2- slightly.

Slide the Engine Control Module (ECM) out of retainer -arrow-.

Scheme 108

Disconnect the rear harness connector from Engine Control Module (ECM).

Engine Control Module (ECM) -J623- installation

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

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

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

Engine Control Module (ECM) -J623

The new Engine Control Module (ECM) -J623- and immobilizer must be activated. Refer to the Repair information for ECM and immobilizer activation instructions.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

SPEED SIGNAL, CHECKING

The following procedure requires a test drive. Observe all Safety Precautions.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Speedometer -G21- OK.
2. The Engine Control Module (ECM) -J623- fuses OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.
7. Ignition switched off.

Test procedure

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

Start diagnosis

Connect the scan tool.

Function test

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

Using the scan tool, Check the vehicle speed

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

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

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

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

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

If necessary, repair the faulty wiring connection.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

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) - J623- fuses OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
6. A/C switched off.
7. Ground connections between engine/transmission/chassis OK.
8. Ignition switched off.

Function

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

If the CAN Bus communication is interrupted. Communication from the scan tool to the Engine Control Module (ECM) -- may not be possible.

Test procedure

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

Start diagnosis

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

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

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

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

If the specified value was Not obtained

Check the wiring 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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

If the specified value was obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Data Bus On Board Diagnostic Interface -J533- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness connector T121 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, 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 specified value was obtained

Replace the Data Bus On Board Diagnostic Interface -J533-.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

THREE WAY 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.

If the specified values are exceeded

Check the exhaust system for leaks.

If necessary, repair the leak in the exhaust system.

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

Perform a road test to verify Repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

If no leaks are found in the exhaust system

Replace the catalytic converter including front exhaust pipe. 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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

SECONDARY AIR 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. Secondary air injection (AIR) solenoid valve -N112- OK.
2. Secondary air injection (AIR) solenoid valve 2 -N320- OK
3. Check vacuum system, including vacuum reservoir in intake manifold, for leaks.
4. Check that the vacuum lines are correctly connected.
5. Check the vacuum hoses for damage.
6. Vacuum lines not plugged.

Test sequence

Remove the vacuum hose from the combination valve.

Connect hand vacuum pump to combination valve vacuum connection.

Scheme 109

Disconnect the Secondary Air Injection hose -arrow-.

Scheme 110

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

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

Operate the hand vacuum pump.

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

If combination valve does not open

Replace the faulty combination valve.

SECONDARY AIR INJECTION SOLENOID VALVE CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB38- OK.
2. The ignition switched off.

Note. Voltage for the Secondary Air Injection (AIR) Solenoid Valve -N112- is supplied by the Power Supply Relay (terminal 30, B+) -J317-.

Test procedure

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

Start diagnosis

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

Checking internal resistance

Using a multimeter, check the resistance between terminals 1 and 2 of the Secondary Air Injection (AIR) Solenoid Valve -N112-.

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

If the specified value was Not obtained

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

If the specified value was obtained

Checking voltage supply

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

Operate the starter briefly.

Specified value: Battery voltage.

If the specified value was Not obtained

Check the wiring connection from the Secondary Air Injection (AIR) Solenoid Valve -N112- electrical harness connector terminal 1 to the Power Supply Relay (terminal 30, B+) -J317- terminal 87 for an open circuit, high resistance, a short circuit to Battery positive (+) or to Ground.

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 Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Secondary Air Injection (AIR) Solenoid Valve -N112- electrical connector terminal 2 to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminal 47 for resistance.

Specified value: 1.5 ohms.

If the specification was Not obtained

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

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

If necessary, repair the wiring connection.

If the specification was obtained

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

SECONDARY AIR INJECTION SOLENOID VALVE 2 CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB38- OK.
2. The ignition switched off.

Note. Voltage for the Secondary Air Injection (AIR) Solenoid Valve 2 -N320- is supplied by the Power Supply Relay (terminal 30, B+) -J317-.

Test procedure

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

Start diagnosis

Disconnect the Secondary Air Injection (AIR) Solenoid Valve 2 -N320- electrical harness connector.

Checking internal resistance

Using a multimeter, check the resistance between terminals 1 and 2 of the Secondary Air Injection (AIR) Solenoid Valve 2 -N320-.

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

If the specified value was Not obtained

Replace the Secondary Air Injection (AIR) Solenoid Valve 2 -N320-.

If the specification was obtained

Checking voltage supply

Using a multimeter, check the Secondary Air Injection (AIR) Solenoid Valve 2 -N320- electrical harness connector terminal 1 to Ground for voltage.

Operate the starter briefly.

Specified value: Battery voltage.

If the specified value was Not obtained

Check the wiring connection from the Secondary Air Injection (AIR) Solenoid Valve 2 -N320- electrical harness connector terminal 1 to the Power Supply Relay (terminal 30, B+) -J317- terminal 87 for an open circuit, high resistance, a short circuit to Battery positive (+) or to Ground.

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 Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Secondary Air Injection (AIR) Solenoid Valve 2 -N320- electrical connector to the Engine Control Module (ECM) -J623- electrical harness connector T121 for resistance.

Specified value: 1.5 ohms.

If the specification was Not obtained

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

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

If necessary, repair the wiring connection.

If the specification was obtained

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

SECONDARY AIR INJECTION PUMP MOTOR CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Secondary Air Injection (AIR) Pump Relay -J299- fuses OK.
2. The Power Supply Relay (terminal 30, B+) -J317- 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

Remove the center noise insulation fasteners -1, 2, 3- and the center noise insulation panel.

Scheme 111

Disconnect the Secondary Air Injection (AIR) Pump Motor -V101- electrical harness connector -3-.

Scheme 112

Checking voltage

Start engine momentarily.

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

Specified value: Battery voltage.

If the specified value was Not obtained

Check the wiring connection from the Secondary Air Injection (AIR) Pump Relay -J299- socket 2/87 to the Secondary Air Injection (AIR) Pump Motor -V101- electrical harness connector terminal 2 for an open circuit, high resistance, or short circuit to each other, Battery (+) or Ground.

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

If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking Ground

Using a multimeter, check the Secondary Air Injection (AIR) Pump Motor -V101- electrical harness connector terminal 1 to Ground connection on left headlamp for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

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

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

If necessary, repair the faulty wiring connection.

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

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

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

SECONDARY AIR INJECTION SENSOR 1 CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Engine Control Module (ECM) - J623- fuses OK.
2. The parking brake engaged.
3. The battery voltage at least 12.5 V.
4. The selector lever of automatic transmission in position "P" or "N".
5. All electrical consumers switched off (radiator fan must NOT run during test).
6. A/C switched off.
7. The fuel tank at least 1 / 4 filled.
8. The ignition switched off.

Test procedure

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

Start diagnosis

Disconnect the Secondary Air Injection Sensor (AIR) 1 -G609,- electrical harness connector.

Checking voltage supply

Switch the ignition On.

Using a multimeter, check the Secondary Air Injection Sensor (AIR) 1 -G609,- electrical harness connector for voltage.

Switch the ignition Off.

If the specified values were obtained

Replace the Secondary Air Injection Sensor (AIR) 1 -G609,-.

If specified values were Not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Secondary Air Injection Sensor (AIR) 1 -G609,- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T121 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

Check the wiring for an open circuit, high resistance, 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 the specification was obtained

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

SECONDARY AIR INJECTION PUMP RELAY CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse -SB29- OK.
2. Fuse -SB51- OK.
3. The Power Supply Relay (terminal 30, B+) -J317- fuse OK.
4. Battery voltage at least 12.5 V.
5. All electrical consumers switched off.
6. A/C switched off.
7. The ignition switched off.

Test procedure

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

Start diagnosis

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

Checking voltage

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

Specified value: Battery voltage.

If the specified value was Not obtained

Check the wiring connection from the Secondary Air Injection (AIR) Pump Relay -J299- socket 1/30 to TV2 (terminal 30 Junction) for an open circuit, a short circuit to each other, Battery (+) and Ground.

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

If necessary, repair the faulty wiring connection.

If the specified value was obtained

Switch the ignition On.

Using a multimeter, check the Secondary Air Injection (AIR) Pump Relay -J299- socket 3/85 to Ground for voltage.

Specified value: Battery voltage.

Switch the ignition Off.

If the specified value was Not obtained

Check the wiring connection from the Power Supply Relay (terminal 30, B+) -J317- socket 87 to the Secondary Air Injection (AIR) Pump Relay -J299- socket 3/85 for an open circuit, high resistance, a short circuit to each other, Battery (+) and Ground.

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

If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, check the Secondary Air Injection (AIR) Pump Relay -J299- to the Engine Control Module (ECM) -J623- electrical harness connector T121 for resistance.

Specified value: 1.5 ohms Max.

If the specification was Not obtained

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

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

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

CAMSHAFT POSITION SENSOR 1 CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Engine Control Module (ECM) - J623- fuses OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground 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

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

Scheme 113

Switch the ignition On.

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

Scheme 114

Specified value: near 5.0 V

Switch the ignition Off.

If the specification was obtained

Replace Camshaft Position (CMP) Sensor -G40-.

If the specification was not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

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

Scheme 115

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.

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

CAMSHAFT POSITION SENSOR 2 CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Engine Control Module (ECM) - J623- fuses OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground 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

Disconnect the Camshaft Position (CMP) Sensor 2 -G163- electrical harness connector -2-.

Switch the ignition On.

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

Specified value: near 5.0 V

Switch the ignition Off.

If the specification was obtained

Replace Camshaft Position (CMP) Sensor 2 -G163-.

If the specification was Not obtained

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, Check the Camshaft Position (CMP) Sensor 2 -G163- electrical harness connector to the Engine Control Module (ECM) electrical harness connector T121 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, short circuit to Battery (+) or Ground.

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

If necessary, repair the faulty wiring connection.

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

KNOCK SENSOR 1 CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The mounting bolt of Knock Sensor (KS) 1 -G61- tightened to 20 Nm.
2. The Engine Control Module (ECM) - J623- fuses OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
6. A/C switched off.
7. Ground connections between engine/transmission/chassis OK.
8. Ignition switched off.

Test procedure

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

Start diagnosis

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

Checking internal resistance

Using a multimeter, check the Knock Sensor (KS) 1 -G61- terminals 1 to 2 for an internal short.

Specified value: infinity (Infinity).

If the specified value was Not obtained

Replace Knock Sensor (KS) 1 -G61-.

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) -J623-. Refer to the Repair Information.

Using a multimeter, Check the Knock Sensor (KS) 1 -G61- electrical harness connector to the Engine Control Module (ECM) J623 electrical harness connector T121 for resistance.

Scheme 116

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.

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

KNOCK SENSOR 2 CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The mounting bolt of Knock Sensor (KS) 2 -G66- tightened to 20 Nm.
2. The Engine Control Module (ECM) - J623- fuses OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
6. A/C switched off.
7. Ground connections between engine/transmission/chassis OK.
8. Ignition switched off.

Test procedure

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

Start diagnosis

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

Checking internal resistance

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

Specified value: infinity (Infinity).

If the specified value was Not obtained

Replace Knock Sensor (KS) 2 -G66-.

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) -J623-. Refer to the Repair Information.

Using a multimeter, Check the Knock Sensor (KS) 2 -G66- electrical harness connector to the Engine Control Module (ECM) J623 electrical harness connector T121 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, short circuit to Battery (+) or Ground.

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

If necessary, repair the faulty wiring connection.

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .

IGNITION COILS WITH POWER OUTPUT STAGE, CHECKING

The following procedure is used to diagnose Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323, N324-.

Special tools and workshop equipment required

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

Test requirements

1. Fuse -SB43- OK.
2. The Power Supply Relay (terminal 30, B+) -J317- 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

Disconnect the Ignition Coil -- electrical harness connectors -1 through 6-.

Scheme 117

Checking voltage supply

Switch the ignition On.

Using a multimeter, check the Ignition Coil -- electrical harness connector terminal 3 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 to the Power Supply Relay (terminal 30, B+) -J317- terminal 87 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 specified value was obtained

Checking activation

Disable the power supply to the Fuel Injectors -- by removing Fuse SB6 (on fuse panel B) from the fuse holder.

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

Operate the starter.

The LED should flicker.

Switch the ignition Off.

If the LED flickers and the voltage was OK

Replace the faulty Ignition Coil --.

If the LED does Not flicker

Checking wiring

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

Install the test box.

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

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Using a multimeter, Check the Ignition Coil -- electrical harness connector to the Engine Control Module (ECM) J623 electrical harness connector T121 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, 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 specified values were obtained

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

Perform a road test to verify repair.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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

Replace the Engine Control Module (ECM) -J623-. Refer to the Repair Information.

Assembly is performed in the reverse of the removal.

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-475603-S16046050632012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475603-S07066265662012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475603-S08201758962012052300000) .