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 SB6 and Fuse SB43.
By removing Fuse SB6, the voltage supply to the Fuel Injectors -- is interrupted. that of by removing Fuse 29 (on fuse panel B) SB29. Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323, N324
By removing Fuse SB43, the voltage supply to the Ignition Coils with Power Output Stage -- is interrupted.
CAMSHAFT POSITION SENSORS G40 AND G163, CHECKING
The following procedure is used to diagnose both Camshaft Position (CMP) Sensor -G40- and Camshaft Position (CMP) Sensor 2 -G163
Note. Use only gold-plated terminals when servicing terminals in harness connectors of Camshaft Position (CMP) Sensor -G40- and Camshaft Position (CMP) Sensor 2 -G163-.
Special tools and workshop equipment required
- Multimeter.
- Wiring diagram.
Test requirements
- The 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
Disconnect the Camshaft Position (CMP) Sensor -G40- electrical harness connector -1- or Camshaft Position (CMP) Sensor 2 -G163- -2-.
Scheme 19
Switch the ignition on.
Using a Multimeter, Check the Camshaft Position (CMP) Sensor -- electrical harness connector terminals 1 to 3 for voltage.
Scheme 20
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 -VAG1598/31-.
If the manufacturers test box is not being used. Perform the following step.
Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REPLACING .
Using a Multimeter, Check the Camshaft Position (CMP) Sensor -G40- or Camshaft Position (CMP) Sensor 2 -G163- electrical harness connector to the Engine Control Module (ECM) electrical harness connector T121 for an open circuit.
Scheme 21
| Camshaft Position (CMP) Sensor 2 -G163- electrical harness connector terminals | Engine Control Module (ECM) electrical harness connector T121 terminals or test box sockets |
|---|---|
| 1 | 98 |
| 2 | 87 |
| 3 | 108 |
| Camshaft Position (CMP) Sensor -G40- electrical harness connector terminals | Engine Control Module (ECM) electrical harness connector T121 terminals or test box sockets |
|---|---|
| 1 | 98 |
| 2 | 86 |
| 3 | 108 |
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- or Camshaft Position (CMP) Sensor 2 -G163-.
If no malfunction is found in the wiring and 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
Repair complete, Generate readiness code. Refer to READINESS CODE DESCRIPTION .
End 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, REPLACING .
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
- Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475605-S30658758892012052300000) .
- If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475605-S15898996512012052300000) .
- If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475605-S28850913172012052300000) .
End of diagnosis
KNOCK SENSOR, CHECKING
The following procedure is used to diagnose Knock Sensor (KS) 1 -G61- / Knock Sensor (KS) 2 -G66-.
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 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
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 22
Checking internal resistance
Using a Multimeter, check the Knock Sensor -- terminals 1 to 2 for an internal short.
Scheme 23
Specified value: infinity (Infinity).
If the specified value was not obtained
Replace the faulty Knock Sensor (KS) 1 -G61- / 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 105 Pin -VAG1598/31-.
If the manufacturers test box is not being used. Perform the following step.
Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REPLACING .
Using a Multimeter, Check the Knock Sensor -- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness connector T121 for an open circuit.
Scheme 24
| Knock Sensor (KS) 1 -G61- electrical harness connector terminals | Engine Control Module (ECM) electrical harness connector T121 terminals or test box sockets |
|---|---|
| 1 | 106 |
| 2 | 99 |
| 3 | 108 |
| Knock Sensor (KS) 2 -G66- electrical harness connector terminals | Engine Control Module (ECM) electrical harness connector T121 terminals or test box sockets |
|---|---|
| 1 | 107 |
| 2 | 99 |
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-.
If no malfunction is found in the wiring and the resistance was OK
Replace the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REPLACING .
Final procedures
After 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-475605-S30658758892012052300000) .
- If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475605-S15898996512012052300000) .
- If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475605-S28850913172012052300000) .
End of diagnosis
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
- Multimeter.
- Diode test lamp.
- Wiring diagram.
Test requirements
- Fuse -SB43- OK.
- The Power Supply Relay (terminal 30, B+) -J317- OK.
- The Engine Speed (RPM) Sensor -G28- OK.
- The Camshaft Position (CMP) Sensor -G40- 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
Disconnect the Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323, N324- electrical harness connectors -1 through 6- from the Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323, N324-.
Scheme 25
Checking voltage supply
Switch the ignition on.
Using a Multimeter, check the Ignition Coil -- electrical harness connector terminals 1 to 4 for voltage.
Scheme 26
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.
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 -- 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 Coils with Power Output Stage -N70, N127, N291, N292, N323, N324-.
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 -VAG1598/31-.
If the manufacturers test box is not being used. Perform the following step.
Remove the Engine Control Module (ECM) -J623-. Refer to ENGINE CONTROL MODULE J623, REPLACING .
Using a Multimeter, Check the Ignition Coil -- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness connector T121 for an open circuit.
| Ignition Coils with Power Output Stage -N70, N127, N291, N292, N323, N324- electrical harness connector terminal | Engine Control Module (ECM) electrical harness connector T121 terminal or test box socket |
|---|---|
| N70/4 | 102 |
| N127/4 | 110 |
| N291/4 | 94 |
| N292/4 | 111 |
| N323/4 | 103 |
| N324/4 | 95 |
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
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 DESCRIPTION .
End 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, REPLACING .
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
- Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475605-S30658758892012052300000) .
- If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475605-S15898996512012052300000) .
- If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475605-S28850913172012052300000) .
End of diagnosis