SAFETY PRECAUTIONS
| WARNING | Observe the following for all installations, especially in the engine compartment due to lack of room: Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed. Watch for sufficient clearance to all moving or hot components. Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. Test equipment must always be secured to the rear seat and operated by a second person. Test and measuring equipment that is operated from the passenger seat, the person seated could be injured in the event of an accident involving deployment of the passenger-side airbag. Do not touch or disconnect ignition wires when engine is running or turning at starting RPM. Only disconnect and reconnect wires for injection and ignition system, including test leads, if the ignition is turned off. |
| WARNING | The use of nails, paper clips, or another unauthorized materials to back-probe electrical harness connectors is strictly prohibited and may cause damage to the electrical harness connectors, terminal ends or damage to a component. Use only the manufacturers test lead kit or an equivalent aftermarket test lead kit for back-probing all electrical harness connectors. |
If engine is to be cranked at starting RPM without starting, e.g. for a compression test
Remove Fuse 6 (on fuse panel B) SB6 and Fuse 29 (on fuse panel B) SB29 from the fuse holder, E-box, plenum chamber.
By removing Fuse 6 (on fuse panel B) SB6, voltage supply of Ignition Coils with Power Output Stage -N70, N127, N291, N292- is interrupted, that of Fuel Injectors -N30, N31, N32, N33- by removing Fuse 29 (on fuse panel B) SB29.
CAMSHAFT POSITION SENSOR G40, CHECKING
Note. Use only gold-plated terminals when servicing terminals in harness connector of Camshaft Position (CMP) Sensor -G40-.
Special tools and workshop equipment required
- Multimeter.
- Wiring diagram.
Test requirements
- The Motronic Engine Control Module (ECM) -J623- fuses OK.
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
- Ignition switched off.
Test procedure
Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK
Start diagnosis
Remove the engine cover with air filter.
Disconnect the Camshaft Position (CMP) Sensor -G40- electrical harness connector -1-.
Scheme 30
Switch the ignition on.
Using a Multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector terminals 1 to 3 for voltage.
Scheme 31
Specified value: about 5.0 V
Switch the ignition off.
If the specification was not obtained
Checking wiring
If the manufacturers test box is being used. Perform the following step.
Install the Test Box 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 Camshaft Position (CMP) Sensor -G40- electrical harness connector to the Motronic Engine Control Module (ECM) electrical harness connector T60 for an open circuit.
Scheme 32
| Camshaft Position (CMP) Sensor -G40- electrical harness connector terminals | Motronic Engine Control Module (ECM) electrical harness connector T60 terminals or test box sockets |
|---|---|
| 1 | 26 |
| 2 | 44 |
| 3 | 13 |
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, lose or broken terminals.
If necessary, repair the faulty wiring connection.
If no malfunction is found in the wiring and voltage supply was OK
Replace the Camshaft Position (CMP) Sensor -G40-. Refer to [For transmission(s) 02E, 02Q] Ignition Components Overview .
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 .
Install the engine cover with air filter.
Final procedures
After the repair work, the following work steps must be performed in the following sequence
- Check the DTC memory «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
- If necessary, erase the DTC memory «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
- If the DTC memory was erased, generate readiness code «READINESS CODE»(ref-475613-S06532716572012052300000) .
End of diagnosis.
KNOCK SENSORS G61 AND G66, CHECKING
The following procedure is used to diagnose all Knock Sensors --.
Special tools and workshop equipment required
- Multimeter.
- Wiring diagram.
Test requirements
- The mounting bolt of Knock Sensor (KS) 1 -G61- / Knock Sensor (KS) 2 -G66- tightened to 20 Nm.
- The Motronic Engine Control Module (ECM) -J623- fuses OK.
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
- Ignition switched off.
Test procedure
Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK
Start diagnosis
Remove the engine cover with air filter.
Note. Before disconnecting the Knock Sensor -- electrical harness connectors, mark the component location.
Disconnect the green Knock Sensor (KS) 1 -G61- electrical harness connector -1- or the gray Knock Sensor (KS) 2 -G66- electrical harness connector -2-.
Scheme 33
Checking internal resistance
Using a Multimeter, check the Knock Sensor -- terminals 1 to 2 for an internal short.
Scheme 34
Specified value: infinity (Infinity).
If the specified value was not obtained
Replace the faulty Knock Sensor (KS) 1 -G61- / Knock Sensor (KS) 2 -G66-. Refer to [For transmission(s) 02E, 02Q] Ignition Components Overview .
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 Knock Sensor -- electrical harness connector to the Motronic Engine Control Module (ECM) J623 electrical harness connector T60 for an open circuit.
Scheme 35
| Knock Sensor (KS) 1 -G61- electrical harness connector terminals | Motronic Engine Control Module (ECM) electrical harness connector T60 terminals or test box sockets |
|---|---|
| 1 | 39 |
| 2 | 54 |
| 3 | 52 |
| Knock Sensor (KS) 2 -G66- electrical harness connector terminals | Motronic Engine Control Module (ECM) electrical harness connector T60 terminals or test box sockets |
|---|---|
| 1 | 9 |
| 2 | 24 |
| 3 | 52 |
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, lose or broken terminals.
If necessary, repair the faulty wiring connection.
If no malfunction is found in the wiring and the resistance was not OK
Replace the faulty Knock Sensor (KS) 1 -G61- / Knock Sensor (KS) 2 -G66-. Refer to [For transmission(s) 02E, 02Q] Ignition Components Overview .
If no malfunction is found in the wiring and the resistance 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
- Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
- If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
- If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .
End of diagnosis.
IGNITION COILS WITH POWER OUTPUT STAGE, CHECKING
The following procedure is used to diagnose all Ignition Coils with Power Output Stage --.
Special tools and workshop equipment required
- Multimeter.
- Diode test lamp.
- Wiring diagram.
Test requirements
- The Ignition Coils with Power Output Stage -N70, N127, N291, N292- fuses OK.
- The Motronic Engine Control Module (ECM) Power Supply Relay -J271- OK, ADD LINK.
- The Engine Speed (RPM) Sensor -G28- OK, «ENGINE SPEED SENSOR G28, CHECKING»(ref-475616-S27641200902012052300000) .
- The Camshaft Position (CMP) Sensor -G40- OK, «CAMSHAFT POSITION SENSOR G40, CHECKING»(ref-475615-S06949345162012052300000) .
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
- Ignition switched off.
Test procedure
Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK
Start diagnosis
Remove the engine cover with air filter.
Remove the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness screws -1-.
Scheme 36
Disconnect the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness connectors -arrows- from the Ignition Coils with Power Output Stage -N70, N127, N291, N292-.
Scheme 37
Checking voltage supply
Switch the ignition on.
Using a Multimeter, check the Ignition Coil -- electrical harness connector terminals 1 to 4 for voltage.
Scheme 38
Specified value: battery voltage.
Switch the ignition off.
If the specified value was not obtained
Check the Ignition Coil -- electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) Power Supply Relay -J271- terminal 2/87 for an open circuit.
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, 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 the specified values were obtained
Checking activation
| WARNING | Do not touch the Ignition Coils -- connecting parts or adapter cables during the following test. |
Disable the power supply to the Fuel Injectors -N30, N31, N32, N33- by removing Fuse 29 (on fuse panel B) from the fuse holder SB29, in the E-box, plenum chamber.
Using a diode test lamp, check the Ignition Coil -- electrical harness connector terminals 1 to 3 for voltage.
Operate the starter.
The LED should flicker.
Switch the ignition off.
If the LED flickers and the voltage was OK
Replace the faulty Ignition Coils with Power Output Stage -N70, N127, N291, N292-. Refer to IGNITION COIL WITH POWER OUTPUT STAGE .
If the 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 Ignition Coil -- electrical harness connector to the Motronic Engine Control Module (ECM) J623 electrical harness connector T60 for an open circuit.
| Ignition Coils with Power Output Stage -N70, N127, N291, 292- electrical harness connector terminal | Motronic Engine Control Module (ECM) electrical harness connector T60 terminal or test box socket |
|---|---|
| 3 | 58 |
| 3 | 41 |
| 3 | 43 |
| 3 | 56 |
Specified value: 1.5 ohms Max.
If the specified value was not obtained
Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
Check the wiring connection for damage, corrosion, lose or broken terminals.
If necessary, repair the faulty wiring connection.
If the specified values were obtained
Replace the Motronic Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .
Connect the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness connectors -arrows- to the Ignition Coils with Power Output Stage -N70, N127, N291, N292-.
Scheme 39
Install the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness screws -1-.
Install the engine cover with air filter.
Final procedures
After the repair work, the following work steps must be performed in the following sequence
- Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475613-S22330328202012052300000) .
- If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475613-S18791737722012052300000) .
- If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475613-S06532716572012052300000) .
End of diagnosis.