2.0L - Multiport Fuel Injection System, Servicing - Engine Code(s): Bpy: Other Volkswagen Eos I

SAFETY PRECAUTIONS

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system. Note the following

1. Always switch off ignition before disconnecting or connecting lines of the fuel injection and ignition system, including test leads.
2. During some of the tests, a Diagnostic Trouble Code (DTC) may be recognized and stored by the control module. At the end of all tests and repairs, the DTC memory should be checked and, if necessary, erased. After erasing the DTC memory, a readiness code must be generated for the engine control module.
3. Always switch ignition off before cleaning engine.

Observe

Note. Observe the following if test and measuring instruments are required during a test drive

CLEAN WORKING CONDITIONS

Even minor contaminations can lead to malfunctions in the fuel injection system. When working on the fuel supply/injection system, pay careful attention to the following rules for cleanliness

1. Thoroughly clean all unions and adjacent areas with engine or brake cleaner and dry before disconnecting.
2. Plug open lines and connections immediately with appropriate protective caps.
3. Place removed parts on a clean surface and cover. Use lint-free cloths.
4. Install clean components: Remove replacement parts immediately prior to installation. Do not use parts that have been stored unpacked (e.g. in tool boxes etc.).
5. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
6. Separated electrical connectors: Protect from dirt and moisture. Make sure connections are dry when reconnecting.

TECHNICAL DATA

COMPONENTS, CHECKING

The following table provides quick links to all the information in this information.

OXYGEN SENSOR HEATER Z19 FOR HEATED OXYGEN SENSOR G39 IN FRONT OF CATALYTIC CONVERTER, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Heated Oxygen Sensor (HO2S) -G39- fuse OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. Ignition switched off.

Test procedure

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

Start diagnosis

Remove the engine cover with air filter.

Checking internal resistance

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

Scheme 134

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- terminals 3+4 for an open circuit.

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

If the specification was not obtained

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

If the specification is obtained

Checking voltage supply

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector terminal 4 to the Engine Component Power Supply Relay -J757- terminal 2 for voltage.

Scheme 135

Specified value: Battery voltage.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

If the specification was obtained

Checking Ground (GND) activation

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

Install the Test Box 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

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

Specified value: 1.5 ohms max.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Install the engine cover with air filter.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

OXYGEN SENSOR HEATER 1 BEHIND THREE WAY CATALYTIC CONVERTER Z29, 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. The Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- fuse OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. 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 136

Checking internal resistance

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

Scheme 137

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

Scheme 138

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

If the specification was not obtained

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

If the specification was obtained

Checking voltage supply

Using a multimeter, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- electrical harness connector terminal 1 to Engine Component Power Supply Relay -J757- terminal 2 for an open circuit.

Specified value: Battery voltage.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

If the specification was obtained

Checking Ground (GND) activation

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

Install the Test Box 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

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

Scheme 139

Specified value: 1.5 ohms max.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Install the right vehicle floor cover.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

MASS AIR FLOW SENSOR G70, CHECKING

Note. Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow (MAF) Sensor -G70-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Mass Air Flow (MAF) Sensor -G70- fuse OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. Coolant Temperature at least 80° C.
8. Ignition switched off.

Function test

Connect the scan tool.

Start engine and let it run at idle.

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

End diagnosis and switch ignition off.

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

Check voltage supply of Mass Air Flow (MAF) Sensor -G70-. Refer to Checking voltage supply .

If specified value was not obtained

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

Checking voltage supply

Disconnect the Mass Air Flow (MAF) Sensor -G70- electrical harness connector -1-.

Scheme 140

Start the engine and let it run at idle.

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

Scheme 141

Specified value: battery voltage.

Switch the ignition off.

If specified value was not obtained

Check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminal 3 to the Power Supply Relay 2 (terminal 15) -J681- terminal 2 for an open circuit.

Specified value: 1.5 ohms max.

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

Checking Ground (GND)

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

Specified value: 1.5 ohms max.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

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

THROTTLE VALVE CONTROL MODULE J338, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) -J623- fuses OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground (GND) connections between engine/transmission/chassis OK.
7. Throttle valve must not be damaged or dirty.
8. Coolant Temperature at least 80° C.

Function

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

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

1. Throttle Drive (for Electronic Power Control (EPC)) -G186
2. Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) -G187
3. Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) -G188

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

Function test

Connect the scan tool.

Switch ignition on.

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

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

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

End diagnosis and switch ignition off.

If the specified values are not obtained

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

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

Scheme 142

Checking resistance

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

Scheme 143

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

If the specification was not obtained

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

If the specification was obtained

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

THROTTLE POSITION SENSOR G79 AND ACCELERATOR PEDAL POSITION SENSOR 2 G185, CHECKING .

Checking voltage supply and wiring

Switch the ignition on.

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

Scheme 144

Specified value: at least 4.5 V

Switch the ignition off.

If the specification was not obtained

Checking wiring

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

Install the Test Box 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Using a Multimeter --, check the Throttle Drive (for Electronic Power Control (EPC)) -G186- at Throttle Valve Control Module -J338- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open circuit according to the wiring diagram.

Scheme 145

Specified value: 1.5 ohms max.

If the specification was not obtained

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

If necessary, repair the faulty wiring connection.

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

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

ENGINE COOLANT TEMPERATURE SENSOR G62, CHECKING

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

Special tools and workshop equipment required

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

Test requirements

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

Function test

Connect the scan tool.

Switch the ignition on.

Using the scan tool, check the coolant temperature

If the specified value is not obtained

Continue test according to the following table

If the specified value was obtained

Start the engine and let it run at idle.

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

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

Replace the Engine Coolant Temperature (ECT) Sensor -G62- COOLING SYSTEM COMPONENTS OVERVIEW, ENGINE SIDE .

Checking internal resistance

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

Scheme 146

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

Scheme 147

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 148

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

If any of the specified values was not obtained

Replace the Engine Coolant Temperature (ECT) Sensor -G62- COOLING SYSTEM COMPONENTS OVERVIEW, ENGINE SIDE .

INTAKE AIR TEMPERATURE SENSOR G42, CHECKING

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

Special tools and workshop equipment required

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

Test requirements

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

Function test

Connect the scan tool.

Switch the ignition on.

Using the scan tool, check the intake air temperature

If the specified value is not obtained

Continue the test according to the following table

If the specified values are obtained

Remove the Intake Air Temperature (IAT) Sensor -G42-. Refer to INTAKE MANIFOLD OVERVIEW .

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

The temperature value must decrease.

End diagnosis and switch the ignition off.

If the intake air temperature does not decrease

Replace the Intake Air Temperature (IAT) Sensor -G42-. Refer to INTAKE MANIFOLD OVERVIEW .

If the intake air temperature does decrease

Checking internal resistance

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

Scheme 149

Using a multimeter, check the Intake Air Temperature (IAT) Sensor -G42- terminals 1 to 2 for resistance.

Use the chart below for the specified values

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

Specified values

Read-out examples

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

If any of the specified values are not obtained

Replace the Intake Air Temperature (IAT) Sensor -G42-. Refer to INTAKE MANIFOLD OVERVIEW .

ENGINE SPEED SENSOR G28, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

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

Test procedure

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

Start diagnosis

The Engine Speed (RPM) Sensor -G28- detects RPM and reference marks. Without an engine speed signal, the engine will not start. If the engine speed signal fails while the engine is running, the engine will stop immediately.

Function test

Connect the scan tool.

Switch the ignition on.

Using the scan tool, check the engine speed

End diagnosis and switch ignition off.

If the specified value was not obtained

Checking internal resistance

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

Scheme 150

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

Scheme 151

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

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

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

Specified value: infinity (infinity)

If any of the specified values are not obtained

Replace the Engine Speed (RPM) Sensor -G28-. Refer to REMOVAL AND INSTALLATION .

If the specified values are obtained

Checking wiring

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

Install the Test Box 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

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

Specified value: 1.5 ohms Max.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Remove the Engine Speed (RPM) Sensor -G28- and check the sensor wheel for proper seating, damage and run-out. Refer to Engine Mechanical, Fuel Injection & Ignition, Fuel Injection & Ignition, Repair Group 13.

If the sensor wheel is OK

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

Perform a road test to verify repair.

If the DTC does not return

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

End diagnosis.

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

Replace the Motronic Engine Control Module (ECM) -J220-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Assembly is performed in the reverse of the removal.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

FUEL INJECTORS N30, N31, N32, AND N33, CHECKING

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

Special tools and workshop equipment required

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

Test requirements

1. The Fuel Injectors -N30, N31, N32, N33- fuses OK.
2. The Engine Speed (RPM) Sensor -G28- OK, checking «ENGINE SPEED SENSOR G28, CHECKING»(ref-475616-S27641200902012052300000) .
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
6. A/C switched off.
7. Ground (GND) connections between engine/transmission/chassis OK.
8. Ignition switched off.

Observe Safety Precautions.

Observe rules for cleanliness.

Test procedure

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

Start diagnosis

Remove the engine cover with air filter.

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

Checking internal resistance

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

Scheme 152

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

If the specified value was not obtained

Replace the malfunctioning Fuel Injector --. Refer to FUEL INJECTORS .

If the specified value was obtained

Checking activation

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

Scheme 153

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

LED should flicker.

Switch the ignition off.

If LED does not flicker

Checking wiring

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

Install the Test Box 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

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

Scheme 154

Specified value: 1.5 ohms Max.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Install the engine cover with air filter.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

INTAKE FLAP MOTOR V157 AND INTAKE MANIFOLD RUNNER POSITION SENSOR G336, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

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

Test procedure

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

Start diagnosis

Remove the engine cover with air filter.

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

Scheme 155

Switch the ignition on.

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

Specified value: about 5 V

Switch ignition off.

If the specified value was obtained

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

If the specified value was not obtained

Checking wiring

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

Install the Test Box 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

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

Specified value: 1.5 ohms Max.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Install the engine cover with air filter.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

FUEL PRESSURE SENSOR G247, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

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

Test procedure

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

Start diagnosis

Remove the engine cover with air filter.

Checking voltage

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

Switch the ignition on.

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

Scheme 156

Switch the ignition off.

If the specified value was obtained

Replace the Fuel Pressure Sensor -G247-. Refer to Fuel Pressure Sensor -G247 .

If the specified value was not obtained

Checking wiring connections

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

Install the Test Box 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Using a Multimeter --, check the Fuel Pressure Sensor -G247- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open circuit according to the wiring diagram.

Specified value: 1.5 ohms Max.

If the specification is not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Install the engine cover with air filter.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

LOW FUEL PRESSURE SENSOR G410, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

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

Test procedure

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

Start diagnosis

Remove the engine cover with air filter.

Checking voltage

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

Scheme 157

Switch the ignition on.

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

Switch the ignition off.

If the specified value was obtained

Replace the Low Fuel Pressure Sensor -G410-. Refer to HIGH PRESSURE PUMP .

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 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

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

Specified value: 1.5 ohms Max.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Install the engine cover with air filter.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

FUEL PRESSURE REGULATOR VALVE N276, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

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

Test procedure

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

Start diagnosis

Remove the engine cover with air filter.

Checking resistance

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

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

Scheme 158

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

If the specified value was not obtained

Replace the Fuel Pressure Regulator Valve -N276-. Refer to HIGH PRESSURE PUMP .

If the specified value was obtained

Checking voltage

Switch the ignition on.

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

Specified value: battery voltage.

Switch the ignition off.

If the specified value was not obtained

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

Check the electrical harness connector for damage, corrosion, lose 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 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ADD LINK.

Using a multimeter --, check the Fuel Pressure Regulator Valve -N276- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open circuit according to the wiring diagram.

Specified value: 1.5 ohms Max.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Install the engine cover with air filter.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

FUNCTIONS, CHECKING

The following table provides quick links to all the information in this information.

HEATED OXYGEN SENSOR G39 AND OXYGEN SENSOR REGULATION BEFORE CATALYTIC CONVERTER, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Heated Oxygen Sensor (HO2S) -G39- fuse OK.
2. The Oxygen Sensor (O2S) Heater -Z19- before catalytic converter OK. Refer to «OXYGEN SENSOR HEATER Z19 FOR HEATED OXYGEN SENSOR G39 IN FRONT OF CATALYTIC CONVERTER, CHECKING»(ref-475616-S20984992172012052300000) .
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.
7. Exhaust system between catalytic converter and cylinder head properly sealed.
8. Coolant Temperature at least 80° C.

Function test

Perform a function test. Refer to DIAGNOSTIC MODE 06 - READ TEST RESULTS FOR SPECIFIC DIAGNOSTIC FUNCTIONS => Test-ID 01 ($01): Oxygen Sensor Monitor Bank 1 - Sensor 1 .

If the specified values are not obtained

Checking primary voltage

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

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

Specified value: above 0.50 Volts

Switch the ignition off.

If the specified value was obtained

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

If the specified value is obtained

Checking wiring

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

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

Specified value: 1.5 ohms Max.

If the specification was not obtained

Check the wiring for a short circuit to each other, positive, or ground.

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

HEATED OXYGEN SENSOR G130 AND OXYGEN SENSOR REGULATION AFTER CATALYTIC CONVERTER, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- fuse Ok.
2. Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater - Z29- OK. Refer to «OXYGEN SENSOR HEATER 1 BEHIND THREE WAY CATALYTIC CONVERTER Z29, CHECKING»(ref-475616-S23222058412012052300000) .
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. Vehicles with automatic transmission, selector lever in position "P" or "N".
6. A/C switched off.
7. Ground (GND) connections between engine/transmission/chassis OK.
8. Exhaust system between catalytic converter and cylinder head properly sealed.
9. Coolant Temperature at least 80° C.

Function test

Perform a function test. Refer to DIAGNOSTIC MODE 06 - READ TEST RESULTS FOR SPECIFIC DIAGNOSTIC FUNCTIONS => Test-ID 02 ($02): Oxygen Sensor Monitor Bank 1- Sensor 2 .

If the specified values are not obtained

Test procedure

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

Start diagnosis

Remove the right vehicle floor cover -arrows-.

Checking primary voltage

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

Switch the ignition on.

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

Scheme 159

Specified value: 0.400 to 0.500 Volts

Switch the ignition off.

If the specified value was obtained

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

If the specified value was not obtained

Checking wiring

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

Install the Test Box 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

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

Specified value: 1.5 ohms Max.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Install the right vehicle floor cover -arrows-.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

ENGINE CONTROL MODULE

The following table provides quick links to all the information in this information.

FUNCTION

Motronic Engine Control Module (ECM) -J623- regulates fuel injection, Throttle Valve Control Module -J338-, oxygen sensor regulation, ignition, knock control, Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-, engine speed limitation through fuel injectors or Fuel Pump (FP) Relay -J17- as well as On Board Diagnostic (OBD).

VOLTAGE SUPPLY, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

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

Test sequence

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

Checking voltage

Using a Multimeter, check the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 1/30 to Ground (GND).

Specified value: battery voltage.

If the specified value was not obtained

Check the wiring connections from the Battery to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 1/30 for an open circuit or a short circuit.

Check the wiring connections for damage, corrosion, lose 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 Motronic Engine Control Module (ECM) Power Supply Relay -J271- socket 3/86 to Ground (GND).

Specified value: battery voltage.

If the specified value was obtained

Checking wiring

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

Install the Test Box 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

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

Specified value: 2.0 ohms Max.

If the specification was not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

Checking activation

Switch the ignition on.

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

Switch the ignition off.

Specified value: 0.5 V Max.

If the specified value was obtained

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

If the specified value was not obtained

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

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

If necessary, repair the faulty wiring connection.

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

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING

Removing

Special tools and workshop equipment required

1. Heat gun.

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

Connect the scan tool.

Switch the ignition on.

Using the scan tool, select "Vehicle information".

Select " Calibration Identification" in vehicle information.

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

Record the electronic control module identification number.

End diagnosis and switch the ignition off.

Procedure

Switch the ignition on.

Actuate the touch-wipe function to allow the wipers to move to the service position.

Scheme 160

Remove the wiper arms caps -arrows-.

Scheme 161

Loosen the wiper arm nuts -arrows- several turns.

Scheme 162

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

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

Remove the spray nozzles -arrow-.

Press the spray nozzles, with the water lines attached, through the plenum chamber opening.

Remove the rubber seal -4- and the plenum chamber cover -1-.

Scheme 163

Note. The threads of the shear bolts have been coated with a locking compound.

Saw off two rounded sides of the shear bolt heads so that two flat parallel surfaces result -arrows-.

Scheme 164

Using locking pliers, remove the shear bolts. Discard the shear bolts.

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

Scheme 165

Using a screwdriver -A-, pry the protective housing upward and sideways to remove from the retaining plate -arrow-.

Scheme 166

Disconnect the forward electrical harness connector -1-.

Lift up the locking mechanism -2- slightly.

Remove the Motronic Engine Control Module (ECM) -J623- from the retainer -arrow-.

Scheme 167

Disconnect the rear electrical harness connector.

Installation

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

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

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

Motronic Engine Control Module (ECM) -J623- reprogramming

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

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

ADDITIONAL SIGNALS, CHECKING

The following table provides quick links to all the information in this information.

SPEED SIGNAL, CHECKING

The following procedure requires a test drive. Observe all Safety Precautions. Refer to "Observe the following if test and measuring instruments are required during a test drive" under SAFETY PRECAUTIONS .

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

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

Function test

Connect the scan tool.

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

Using the scan tool, Check the vehicle speed

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

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

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

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

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

If necessary, repair the faulty wiring connection.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis

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

Function

The Motronic Engine Control Module (ECM) -J623- communicates with other CAN-Bus capable control modules.

The control modules are connected by two data bus wires which are twisted together (CAN_High and CAN_Low), and exchange information (messages). Missing information on the CAN-bus is recognized as a malfunction by the Motronic Engine Control Module (ECM) -J623- and the other control modules connected to the CAN-bus.

Trouble-free operation of the CAN-Bus requires that it have a terminal resistance. This central terminal resistance is located in the Motronic Engine Control Module (ECM) -J623-.

Test procedure

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

Start diagnosis

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

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

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

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

If the specified value was not obtained

Checking wiring

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

Install the Test Box 105 Pin VAG1598/42.

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

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

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

Specified value: 1.5 ohms Max.

If the specified value was not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

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

Perform a road test to verify repair.

If the DTC does not return

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

End of diagnosis

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

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

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .

End of diagnosis