2.0L - Generic Scan Tool - Engine Code(s): Cbfa: Other Volkswagen Eos I рестайлинг

SAFETY PRECAUTIONS

CLEAN WORKING CONDITIONS

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

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place removed parts on a clean surface and cover. Use lint-free cloths.
3. Carefully cover over opened components or seal, if repairs are not performed immediately.
4. When the system is open, do not work with compressed air. Do not move vehicle unless absolutely necessary.
5. Install clean components: Remove replacement parts immediately prior to installation. Do not use parts that have been stored unpacked (e.g. in tool boxes etc.).
6. Separated electrical connectors: Protect from dirt and moisture. Make sure connections are dry when reconnecting.

MALFUNCTION INDICATOR LAMP ILLUMINATION

If the engine control module (ECM) recognizes a malfunction that leads to increased emission values, it indicates them by illuminating the malfunction indicator lamp (MIL) which is located in the instrument cluster.

The ECM switches on the MIL after the ignition is switched on. Shortly after the engine is started, the MIL goes out if the ECM does not detect a malfunction that increases the emission values.

If the ECM recognizes a malfunction that leads to increased emissions during the operation of the engine, the ECM switches on the MIL and an entry is stored in the DTC memory of the ECM.

CONTROLLER AREA NETWORK DATA LINK

The engine control module (ECM) communicates with data bus capable control modules via a CAN Data Link.

The data bus capable control modules are connected via data bus wires, which are twisted together (CAN high and CAN low), and exchange information with the ECM. Missing or implausible information on the data bus is recognized and stored as a malfunction based on specific DTC criteria.

The malfunction indicator lamp (MIL) is illuminated as a result of a CAN message sent by the ECM. The MIL can be turned on, turned off, or blink, depending on the message received.

ELECTRONIC POWER CONTROL WARNING LAMP

The engine control module (ECM) monitors electronic power control (EPC) components when the ignition is switched on.

If a malfunction is recognized in the EPC system, the ECM switches on the EPC warning lamp, which is located in the instrument cluster, and an entry is stored in the DTC memory of the ECM.

FUEL SUPPLY SYSTEM

For all fuel supply system component locations, removal/installation procedures and torque specifications, refer to the service information.

EVAPORATIVE EMISSION SYSTEM

The evaporative emission system has been designed to minimize the release of hydrocarbons from the fuel system into the atmosphere. The evaporative system components all work together with the ECM to prevent fuel vapor from escaping and route it to the intake manifold to be burned during normal combustion.

The leak detection system checks the integrity of the evaporative emission system by pressurizing system.

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

Leak diagnosis is activated automatically shortly following every engine start. If a malfunction is determined, an entry is made to the DTC memory. The Malfunction Indicator Lamp in the instrument cluster is illuminated if the malfunction is recognized for two subsequent starts.

For all evaporative system component locations, hose routing, removal/installation procedures and torque specifications, refer to the service information.

ELECTRONIC ENGINE POWER CONTROL

For EPC, the throttle valve is not operated by a cable from the accelerator pedal. There is no mechanical connection between the accelerator pedal and the throttle valve.

The position of the accelerator pedal is communicated to engine control module (ECM) by the throttle position sensor / accelerator pedal position sensor 2 (variable resistances; stored in one housing) that are connected with the accelerator pedal.

The accelerator pedal position (driver's intention) is a main input unit for the ECM.

Operation of the throttle valve occurs via an electric motor, the throttle drive for in the throttle valve control module. This is true across the entire engine speed and engine load spectrum.

The throttle valve is operated by the EPC according to specifications of engine control module (ECM).

With engine off and ignition switched on, the ECM controls the throttle drive according to specifications of throttle position sensor / accelerator pedal position sensor 2. This means, if the accelerator pedal is pressed half way, the throttle drive opens the throttle valve to the same degree; i.e. throttle valve is then opened approximately half way.

With engine running under load, ECM can open or close the throttle valve independently of the throttle position sensor / accelerator pedal position sensor 2.

This means, for example, that the throttle valve could be fully opened even though the accelerator pedal has only been pressed half way. This has the advantage of preventing torque losses at the throttle valve.

In addition, it results in a significant reduction in emissions and fuel consumption under certain load conditions.

It would be incorrect to think that EPC consists of only one or two components. EPC is much more of a system containing all components that contribute to recognizing, controlling and monitoring the position of the throttle valve.

FUEL INJECTION SYSTEM

For all fuel injection system component locations, removal/installation procedures and torque specifications, refer to the service information.

ENGINE CONTROL MODULE

The ECM regulates fuel injection, throttle valve control module, oxygen sensor regulation, ignition, knock control, evaporative emission purge valve, engine speed limitation through the fuel injectors or the power supply relay, as well as OBD functions.

EXHAUST SYSTEM COMPONENTS

For all exhaust system, emission control component locations, removal/installation procedures and torque specifications, refer to the service information.

SECONDARY AIR INJECTION SYSTEM

The secondary air injection system improves the secondary oxidation within the catalytic converter which are due to the rich mixture during the cold start phase where the exhaust emissions contain an increased level of unburned hydrocarbons, thereby reducing harmful emissions. The heat released by secondary oxidation shortens the startup time of the catalytic converter considerably, as well as significantly improves emissions quality during the cold-running phase.

1. During a cold start, the secondary air injection system injects air behind the exhaust valves. This produces an oxygen rich exhaust gas, causes the after burning and reduces the heating-up phase of the catalytic converter.
2. In addition, the secondary air injection system is switched on (after a delay) during idle after every subsequent engine start (up to a maximum coolant temperature) and is checked through on board diagnostic functions.

For all secondary air injection system component locations, removal/installation procedures and torque specifications, refer to the service information.

IGNITION SYSTEM

For all ignition and glow plug system component locations, removal/installation procedures and torque specifications, refer to the service information.

AUTOMATIC TRANSMISSION

The transmission control module receives information from transmission related components and uses this information to control shifting and operation of the transmission.

For all automatic transmission component locations, removal/installation procedures and torque specifications, refer to the service information.

PRELIMINARY CHECK

Prior to component diagnosis, a preliminary check must be performed.

Connect the scan tool.

Switch the ignition on.

Using the scan tool, check for any stored or related DTCs.

If other DTCs are stored

Repair these DTCs first before performing the following procedure.

If no other DTCs are stored

Using the scan tool, erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .

Perform a road test to attempt to duplicate the customers complaint.

If the DTC returns

Perform the diagnostic procedure.

If the DTC does not return

The fault is intermittent or a sporadic condition may exist.

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

If necessary, repair the faulty wiring connection.

Perform a road test to verify the repair.

If the DTC returns

Perform the diagnostic procedure.

If the DTC does not return

The fault may have been the result of a loose electrical connection.

Generate readiness code. Refer to READINESS CODE .

READINESS CODE

Readiness code description

Diagnostics are performed at regular intervals during normal vehicle operation. After repairing an emissions related system, a readiness code is generated by road testing the vehicle.

If a malfunction is recognized during the drive cycle, it will be stored in the DTC memory.

The OBD drive cycle operation will be monitored with a hand held diagnostic tool. Consult the manufacturer's instruction 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.

FUEL PUMP DELIVERY QUANTITY, CHECKING

Special tools and workshop equipment required

1. Switched remote control (jumper).
2. Multimeter.
3. Electrical connector test lead set.
4. Fuel pressure test set.
5. Measuring container, fuel-resistant.

Test conditions

1. Battery voltage 12.5 V
2. Fuel filter OK
3. Fuel tank at least 1 / 4 filled.
4. Fuel pressure regulator OK.
5. Ignition switched Off.

Test procedure

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

Start diagnosis

Remove the fuel filler cap from fuel filler tube.

Remove rear seat bench.

Remove the floor sealing cover -1-.

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

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

Connect a jumper wire from terminal -5- of the fuel delivery unit to vehicle Ground.

Scheme 61

Disconnect the fuel return line -arrow- by pressing release buttons.

Scheme 62

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

Scheme 63

Press the switch on the remote control (jumper) and operate the fuel pump for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in the diagram (cm 3 /30 sec.).

Scheme 64

Note. Voltage at the fuel pump with engine stopped and fuel pump running is approx. 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

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

If necessary, repair any pinched or plugged lines.

If the filter is restricted

Replace the fuel filter.

If the fuel pump is faulty

Replace the fuel pump.

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

Install the rear seat bench.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

FUEL PRESSURE SENSOR, 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- view -1- electrical harness connector terminals for voltage.

Scheme 65

Switch the ignition Off.

If the specified value was obtained

Replace the Fuel Pressure Sensor -G247-.

If the specified value was Not obtained

Checking wiring connections

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

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 chart below.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

FUEL PRESSURE REGULATOR VALVE, 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- from the Fuel High Pressure Pump -- -1-.

Scheme 66

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

Scheme 67

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

If the specified value was Not obtained

Replace the Fuel Pressure Regulator Valve -N276-.

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 for voltage.

Scheme 68

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- relay terminal 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 a short was found, replace fuse if blown.

If no malfunctions are found in the wiring

Checking wiring

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

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. Refer to appropriate SYSTEM WIRING DIAGRAMS information.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunctions are found in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

EVAP SYSTEM, CHECKING FOR LEAKS

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 and 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 was set and does not return

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

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

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

EVAPORATIVE EMISSION CANISTER SYSTEM, CHECKING FOR PROPER SEAL

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

Test procedure

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

Start diagnosis

Connect the scan tool.

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

Select "Diagnostic mode 8: Tank leak test".

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

Specified value: test OK

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

If the specified value was obtained

Switch the ignition off.

If the specified value was Not obtained

Checking fuel supply and tank ventilation systems for leaks

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

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

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

1. Check the line from the EVAP canister to the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-.
2. Check the lines from the EVAP canister to the Leak Detection Pump (LDP) -V144-.
3. Check the line from the fuel tank to the EVAP canister (below cover for EVAP canister).
4. Check the lines for the tank ventilation (beneath right rear wheel housing liner).
5. Check the fuel lines to the engine.
6. Remove the rear seat bench.
7. Remove the floor cover seal.
8. Inspect the seal under the Fuel Delivery Unit (fuel pump) locking flange for proper sealing. Also check the fuel line connections.

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

Repeat the function test.

If a leak is detected

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

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

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

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

EVAPORATIVE EMISSION CANISTER PURGE REGULATOR VALVE, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- fuse OK.
2. The ignition switched Off.

Note. Voltage for the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- is supplied via the Engine Component Power Supply Relay -J757-.

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 Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- electrical harness connector -1-.

Scheme 69

Checking internal resistance

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

Scheme 70

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 specified value was obtained

Checking voltage supply

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

Scheme 71

Turn ignition switch On.

Specified value: 10.6 volts +/- 2 volts.

If the specified value was Not obtained

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

Ignition switch On.

Specified value: Battery voltage.

Turn ignition switch Off.

If the specified value was Not obtained

Check the wire from the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- electrical harness connector terminal 1 to fuse 24 in Fuse Panel B for an open or high resistance.

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

If necessary, repair the wiring connection.

If the specified value was obtained

Check Ground activation

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

Using a multimeter, check the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- electrical connector terminal 2 to the Motronic Engine Control Module (ECM) -J623- electrical connector T60 terminal 35 for an open circuit.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

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

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

If necessary, repair the wiring connection.

If the specified value was obtained

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

LEAK DETECTION PUMP, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Leak Detection Pump (LDP) -V144- fuse 15 in fuse panel B is OK.
2. The ignition switched Off.

Test procedure

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

Start diagnosis

Remove the right rear wheel housing liner.

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

Scheme 72

Checking internal resistance

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

Scheme 73

If the specified values were Not obtained

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

If the specified values are obtained

Checking voltage supply

Note. The voltage for the Leak Detection Pump (LDP) --V144-- is supplied via fuse 15 in fuse panel B.

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

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

Scheme 74

Turn the ignition switch On.

Specified value: Battery voltage.

Switch the ignition Off.

If the specified value was Not obtained

Remove fuse 15 in Fuse Panel B. Using a multimeter, check the Leak Detection Pump (LDP) --V144-- wiring from terminal 3 to fuse 15 in Fuse Panel B.

Specified value: Wire resistance max 1.5 ohms.

If the specified value was Not obtained

Check the wiring for high resistance or an open circuit.

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

If necessary, repair the faulty wiring connection.

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

Checking wiring

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

Using a multimeter, check the Leak Detection Pump (LDP) --V144-- electrical connector terminal 1 to Motronic Engine Control Module (ECM) -J623- electrical connector T94 terminal 44 for an open circuit or high resistance.

Using a multimeter, check the Leak Detection Pump (LDP) --V144-- electrical connector terminal 2 to Motronic Engine Control Module (ECM) -J623- electrical connector T94 terminal 49 for an open circuit or high resistance.

Scheme 75

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for high resistance or an open circuit.

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in wiring

Replace the Motronic Engine Control Module (ECM) -J623-.

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

Install the right rear wheel housing liner.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

ACCELERATOR PEDAL POSITION SENSOR 1/ACCELERATOR PEDAL POSITION SENSOR 2, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram

Test requirement

1. The Motronic Engine Control Module (ECM) - 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 Accelerator Pedal Position Sensor 1 -G79- /Accelerator Pedal Position Sensor 2 -G185-.

Test procedure

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

Start diagnosis

Remove the drivers side storage compartment.

Disconnect the Accelerator Pedal Position Sensor 1 -G79-/Accelerator Pedal Position Sensor 2 -G185- 6 pin electrical harness connector -2-.

Scheme 76

Checking voltage supply and wiring

Switch the ignition On.

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

Scheme 77

Switch the ignition Off.

If the specified value was Not obtained

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

Install the test box.

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

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

Using a multimeter, check the Accelerator Pedal Position Sensor 1 -G79- /Accelerator Pedal Position Sensor 2 -G185- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical connector T94 for an open circuit.

Scheme 78

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for a short circuit to each other, voltage, Ground or high resistance.

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

If necessary, repair the faulty wiring connection.

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

Replace the Accelerator Pedal Position Sensor 1 -G79- /Accelerator Pedal Position Sensor 2 -G185-.

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

Replace the Motronic Engine Control Module (ECM) -J623-.

Install the drivers side storage compartment.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

THROTTLE VALVE CONTROL MODULE, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Motronic Engine Control Module (ECM) - 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 referred to as the Throttle Drive Motor -G186- located in the Throttle Valve Control Module - J338-. It is controlled by the Motronic Engine Control Module (ECM) -J623- with input from the Accelerator Pedal Position Sensor 1 -G79- /Accelerator Pedal Position Sensor 2 -G185- and throttle drive angle sensors.

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

1. Throttle Drive Motor -G186
2. Throttle Drive Angle Sensor 1 -G187
3. Throttle Drive Angle Sensor 2 -G188

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

Test procedure

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

Start diagnosis

Connect the scan tool.

Switch ignition On.

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

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

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

Switch ignition Off.

If the specified value was 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 79

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 80

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

If the specified value was Not obtained

Replace the Throttle Valve Control Module - J338-.

If the specified value was obtained

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

Checking voltage supply and wiring

Switch the ignition On.

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

Scheme 81

Specified value: at least 4.5 V

Switch the ignition Off.

If the specified value was Not obtained

Checking wiring

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

Using a multimeter, check the 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. Refer to appropriate SYSTEM WIRING DIAGRAMS information.

Scheme 82

Specified value: 1.5 ohms max.

If the specified value was Not obtained

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

If necessary, repair the faulty wiring connection.

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

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

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

TURBOCHARGER RECIRCULATING VALVE, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

Scheme 83

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. On vehicles with automatic transmission, selector lever in position "P" or "N".
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.
7. Ignition switched Off.

Test procedure

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

Start diagnosis

Lift the vehicle on a hoist to access the turbocharger recirculating valve connector.

Checking internal resistance

Disconnect the Turbocharger Recirculating Valve -N249- electrical harness connector -2-.

Scheme 84

Using a multimeter, check the Turbocharger Recirculating Valve -N249- terminals 1 to 2 for resistance.

Specified value: 13.6 ohms +/- 5 ohms (at room temperature)

If the specified value was Not obtained

Replace the Turbocharger Recirculating Valve -N249-.

If the specified value was obtained

Checking Voltage supply

Using a multimeter, check the Turbocharger Recirculating Valve -N249- electrical harness connector terminal 1 to engine ground.

Start the engine.

Specified value: Battery voltage.

Switch the ignition Off.

If the specified value was Not obtained

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

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

Using a multimeter, check the Turbocharger Recirculating Valve -N249- electrical harness connector terminal to Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 for an open circuit.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for an open or high resistance.

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

If necessary, repair the faulty wiring connection.

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

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

WASTEGATE BYPASS REGULATOR VALVE, 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. On vehicles with automatic transmission, selector lever in position "P" or "N".
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.
7. Ignition switched Off.

Test procedure

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

Start diagnosis

Remove the engine cover with air filter.

Checking internal resistance

Disconnect the Wastegate Bypass Regulator Valve -N75- electrical harness connector -1-.

Using a multimeter, check the Wastegate Bypass Regulator Valve -N75- terminals 1 to 2 for resistance.

Specified value: 20 to 30 ohms (at approx. 20° C)

If the specified value was Not obtained

Replace the Wastegate Bypass Regulator Valve -N75-.

If the specified value was obtained

Checking Voltage supply

Start the engine.

Using a multimeter, check the Wastegate Bypass Regulator Valve -N75- electrical harness connector terminal 1 to engine ground.

Specified value: Battery voltage.

Switch the ignition Off.

If the specified value was Not obtained

Check the wiring for a short circuit to ground, high resistance or an open circuit to fuse SB24.

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

If necessary, repair the wiring connection.

If the specified value was obtained

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

Using a multimeter, check the Wastegate Bypass Regulator Valve -N75- electrical harness connector terminal to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 for an open circuit.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for an open or high resistance.

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

If necessary, repair the faulty wiring connection.

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

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

CHARGE AIR PRESSURE SENSOR, CHECKING

Note. Use only gold-plated terminals when servicing terminals in harness connector of Charge Air Pressure Sensor -G31-.

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. On vehicles with automatic transmission, selector lever in position "P" or "N".
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.
7. Ignition switched Off.

Test procedure

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

Start diagnosis

Remove the engine cover.

Test sequence

Disconnect the Charge Air Pressure Sensor -G31- electrical harness connector -arrow-.

Scheme 85

Start the engine.

Using a multimeter, check the Charge Air Pressure Sensor -G31- electrical harness connector terminals 1 to 3 for voltage.

Specified value: 4.5 to 5.2 V

Switch the ignition Off.

If the specified value was Not obtained

Checking wiring

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

Using a multimeter, check the Charge Air Pressure Sensor -G31- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open circuit according to wiring diagram.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

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

If necessary, repair the faulty wiring connection.

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

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

Replace the Charge Air Pressure Sensor -G31-.

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

Replace the Motronic Engine Control Module (ECM) -J623-.

Install the engine 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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

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 -G39- before catalytic converter OK.
3. Battery voltage at least 12.5 volts.
4. All electrical consumers such as, lights and rear window defroster, switched off.
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.
7. Exhaust system between catalytic converter and cylinder head properly sealed.
8. Coolant Temperature at least 80 °C.

Test procedure

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

Start diagnosis

Connect scan tool.

Start the engine and let it run at idle.

Select "Diagnostic Mode 6: Check test results of components that are not continuously monitored".

Select "Monitor-ID 01: Oxygen sensor monitoring before catalytic converter".

Select "Test-ID $89: Dynamic test".

Check the specified values at idle.

If the specified value was obtained

Switch the ignition Off. Fault is not active at this time. Check for poor connections, loose terminals and harness check.

If the specified value was Not obtained

Checking primary voltage

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

Turn the ignition On.

Scheme 86

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G39- electrical harness connector -1- terminals 1 to 2 for voltage.

Turn the ignition On.

Scheme 87

Specified value: 0.400 to 0.500 Volts

If the specified value was obtained

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

If the specified value was Not obtained

Checking wiring

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

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 specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

OXYGEN SENSOR HEATER BEFORE 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 15 in Fuse Panel B is OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.
7. Ignition switched Off.

Test procedure

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

Start diagnosis

Remove the engine cover with air filter.

Checking internal resistance

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

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

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

If the specified value was Not obtained

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

If the specified value was obtained

Checking voltage supply

Turn the ignition switch ON

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

Specified value: Battery voltage.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking Ground activation

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

Install the test box.

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

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

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

Specified value: 1.5 ohms max.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

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

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

OXYGEN SENSOR REGULATION IN CENTER THREE WAY CATALYTIC CONVERTER, CHECKING

Note. Use only gold-plated terminals when servicing terminals in the electrical harness connectors of the Oxygen Sensor (O2S) 2 in center Three Way Catalytic Converter (TWC) -G108-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. Fuse 21 in Fuse Panel B is OK.
2. 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

Perform the function test in Diagnostic Mode 06.

If specified values are obtained

Check for possible intermittent connection or rub through of harness.

If the specified value was Not obtained

Checking primary voltage

Disconnect the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G108- electrical harness connector.

Scheme 88

Switch the ignition On.

Using a multimeter, check the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G108- electrical harness connector terminals 3 to 4 for voltage.

Specified value: 0.400 to 0.500 Volts

Switch the ignition Off.

If the specified value was obtained

Replace the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G108-.

If the specified value was Not obtained

Checking wiring

Remove the Engine Control Module (ECM) -J623-.

Using a multimeter, check the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G108- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T94 terminals for resistance.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

Check the wiring for an open, high resistance, short circuit to each other, voltage, 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 active fault.

If the DTC does not return

Generate readiness code. Refer to READINESS CODE .

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-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

OXYGEN SENSOR HEATER IN CENTER THREE WAY CATALYTIC CONVERTER, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Heated Oxygen Sensor (HO2S) -G108- fuse 21 in Fuse Panel B is OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.
7. Ignition switched Off.

Test procedure

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

Start diagnosis

Remove the engine cover with air filter.

Checking internal resistance

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

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G108- terminals 1 and 2 for correct resistance.

Scheme 89

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

If the specified value was Not obtained

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

If the specified value was obtained

Checking voltage supply

Turn the ignition switch ON

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G108- electrical harness connector terminal 1 to engine ground for voltage.

Specified value: Battery voltage.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking Ground activation

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

Using a multimeter, check the Heated Oxygen Sensor (HO2S) -G108- electrical harness connector terminal to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T94 for an open circuit.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for an open or high resistance.

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

If necessary, repair the faulty wiring connection.

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

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

OXYGEN SENSOR REGULATION BEHIND 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 3 and 4 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 21 in Fuse Panel B is OK.
2. Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC)) Heater - G130- 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, selector lever in position "P" or "N".
6. A/C switched off.
7. Ground connections between engine/transmission/chassis OK.
8. Exhaust system between catalytic converter and cylinder head properly sealed.
9. Coolant Temperature at least 80 °C.

Test procedure

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

Start diagnosis

Connect scan tool.

Start the engine and let it run at idle.

Select "Diagnostic mode 6: Check test results of components that are not continuously monitored".

Select "Monitor-ID 02: Oxygen sensor monitoring behind catalytic converter".

Select following Test-IDs.

Check the specified values at idle and compare the results to the min/max values given in the Mode 6 table.

If the specified values were obtained

Switch ignition Off. Fault is not active at this time. Check for poor connections, loose terminals and harness check.

If the specified values were Not obtained

Remove the right vehicle floor cover -arrows-.

Checking primary voltage

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

Scheme 90

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 91

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

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

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 chart below.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring and the voltage was NOT present

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

OXYGEN SENSOR HEATER BEHIND CATALYTIC CONVERTER, 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) Heater Behind Three Way Catalytic Converter (TWC) -G130- fuse 21 in Fuse Panel B is OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.
7. Ignition switched Off.

Test procedure

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

Start diagnosis

Remove the right vehicle floor cover -arrows-.

Checking internal resistance

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

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 92

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

If the specified value was Not obtained

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

If the specified value was obtained

Checking voltage supply

Turn the ignition switch On.

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

Specified value: Battery voltage.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

If the specified value was obtained

Checking Ground activation

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

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

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for an open or high resistance.

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

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

MAF SENSOR, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

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

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

Fault may be intermittent. Check the electrical harness connector for damage, corrosion, loose or broken terminals.

If the specified value was Not obtained

Checking voltage supply

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

Scheme 93

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.

Scheme 94

Specified value: Battery voltage.

Switch the ignition Off.

If the specified value was Not obtained

Remove the fuse 1 in Fuse Panel C. Check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminal 3 to Fuse 1 in Fuse Panel C for an open circuit.

Specified value: 1.5 ohms max.

If the specified value was obtained

Checking electrical circuit

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

Using a multimeter, check the Mass Air Flow (MAF) Sensor -G70- 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 specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

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

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

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

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

ENGINE COOLANT TEMPERATURE SENSOR 1 OR 2 CHECKING

Note. ECT 1 is identified as G62 and is located on the thermostat housing. ECT 2 is identified as G83 and is located on the lower radiator hose. Use only gold-plated terminals when servicing terminals in the electrical harness connector of Engine Coolant Temperature (ECT) Sensor -G62 or G83

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 connections between engine/transmission/chassis OK.
7. Ignition switched OFF.
8. Engine should be cold to verify low temperature readings and monitor increase while engine is running.

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 reading is out of range, continue test according to the following table

If the specified value was obtained

Start the engine and let it run at idle.

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

Turn the ignition switch OFF

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

Replace the Engine Coolant Temperature (ECT) Sensor - G62 or 83

Checking internal resistance

Disconnect the Engine Coolant Temperature (ECT) Sensor - G62 or 83- electrical harness connector.

Using a multimeter, check the Engine Coolant Temperature (ECT) Sensor - G62 or 83- terminals 1 to 2 for resistance.

Use the chart below for the specified values

Specified values

If the specified values were Not obtained

Replace the Engine Coolant Temperature (ECT) Sensor - G62 or 83

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

INTAKE AIR TEMPERATURE SENSOR, CHECKING

Note. Use only gold-plated terminals when servicing terminals in the electrical harness connector of the IAT sensor -G42-.

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test procedure

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

Start diagnosis

Connect the scan tool.

Engine MUST be at room temperature.

Switch the ignition On.

Using the scan tool, check the intake air temperature

Switch the ignition Off

If the specified value was obtained

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

If the specified value was Not obtained

Checking internal resistance

Disconnect the IAT sensor -G42- electrical harness connector.

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

Use the chart below for the specified values

Specified values

If the specified value was Not obtained

Replace the IAT sensor -G42-.

If the specified values are obtained, continue the test according to the following table

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

AMBIENT AIR TEMPERATURE SENSOR, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test procedure

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

Start diagnosis

Connect the scan tool.

Engine MUST be at room temperature.

Turn the ignition switch ON.

Using the scan tool, check the ambient air temperature

Turn the ignition switch OFF.

If the specified value was obtained

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

Note. The scan tool reading may default to 419 °F if the circuit is open or shorted to ground. The display on the cluster may show 3 dashes.

If the specified value was Not obtained

Checking internal resistance

Disconnect the Ambient Air Temperature Sensor -G17- electrical harness connector.

Using a multimeter, check the Ambient Air Temperature Sensor -G17- terminals 1 to 2 for resistance.

Use the chart below for the specified values

Specified values

If the specified values were Not obtained

Replace the Ambient Air Temperature Sensor -G17-.

If the specified values are obtained, continue the test according to the following table

Checking wiring

Turn the ignition switch ON.

Connect a multimeter to terminals 1 and 2 of the Ambient Air Temperature Sensor -G17- electrical harness connector.

Specified value: near 5.02 V

Turn the ignition switch OFF.

If the specified value was Not obtained

Remove the Instrument Cluster.

Disconnect the Instrument Cluster harness.

Using a multimeter, check the Ambient Air Temperature Sensor -G17- electrical harness connector terminals 1 and 2 to the Instrument Cluster electrical harness connector for an open circuit or a short. Refer to the wiring diagram.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the wiring for an open, high resistance or short 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 the specified value was obtained

Replace the Instrument Cluster.

Final procedures

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

ENGINE SPEED SENSOR, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

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

Test procedure

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

Start diagnosis

Connect the scan tool.

Start the engine and allow it to idle.

Using the scan tool, check the engine speed

Switch ignition Off.

If the specified value was Not obtained

Checking internal resistance

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

Using a multimeter, check the Engine Speed (RPM) Sensor -G28- terminals 1 to 2 for resistance.

Scheme 95

Specified value: 650 to 1100 ohms

If the specified value was Not obtained

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

If the specified value was obtained

Checking wiring

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

Install the test box.

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

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

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. Refer to the appropriate system Wiring Diagrams information.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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.

If the sensor wheel is OK

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

FUEL INJECTORS, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. 12V diode test lamp
3. Wiring diagram.

Test requirements

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

Observe safety precautions.

Observe rules for cleanliness.

Test procedure

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

Start diagnosis

Remove the engine cover.

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

Scheme 96

Checking internal resistance

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

Scheme 97

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

If the specified value was Not obtained

Replace the malfunctioning Fuel Injector --.

If the specified value was obtained

Checking activation and wiring

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

Scheme 98

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

LED should flicker.

Switch the ignition Off.

If LED does not flicker

Remove the Engine Control Module (ECM) -J623-.

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

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Replace the Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

INTAKE MANIFOLD RUNNER CONTROL VALVE, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The Intake Manifold Runner Control (IMRC) Valve -N316- fuse SB-24 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 Intake Manifold Runner Control (IMRC) Valve -N316- electrical harness connector.

Checking internal resistance

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

Specified value: 25 (+/- 10) ohms.

If the specified value was Not obtained

Replace the Intake Manifold Runner Control (IMRC) Valve -N316-.

If the specified value was obtained

Checking voltage

Switch the ignition On.

Using a multimeter, check the Intake Manifold Runner Control (IMRC) 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 (IMRC) Valve -N316- electrical harness connector terminal 1 to fuse 24 on Fuse Panel B.

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

Remove the Engine Control Module (ECM) -J623-.

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

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

Check the wiring for a open circuit.

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

If necessary, repair the faulty wiring connection.

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

Replace the Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

INTAKE MANIFOLD RUNNER POSITION SENSOR, 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 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 Manifold Runner Position Sensor -G336- electrical harness connector -arrow-.

Scheme 99

Switch the ignition On.

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

Specified value: near 5 V

Switch ignition Off.

If the specified value was obtained

Replace the Intake Manifold Runner Position Sensor - G336-.

If the specified value was Not obtained

Checking wiring

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

Using a multimeter, check the 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 specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is detected in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

VOLTAGE SUPPLY, CHECKING

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, selector lever in position "P" or "N".
5. A/C switched off.
6. Ground connections between engine/transmission/chassis OK.
7. Ignition switched OFF.

Test procedure

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

Start diagnosis

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

Checking voltage

Using a multimeter, check the Engine Control Module (ECM) Power Supply Relay -J271- relay terminal 30 to Ground.

Specified value: Battery voltage.

If the specified value was Not obtained

Check the wiring connections from the Battery to the Engine Control Module (ECM) Power Supply Relay -J271- relay terminal 30 for an open, high resistance or a short circuit.

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 Engine Control Module (ECM) Power Supply Relay -J271- relay terminal 85 to Ground.

Specified value: Battery voltage.

Switch the ignition OFF.

If the specified value was Not obtained

Remove Fuse 10 in Fuse Panel B and check resistance of circuit between fuse and relay terminal 85.

Specified value: 1.5 ohm or less.

If fuse is blown, locate short to ground in circuit, refer to appropriate system wiring diagram information.

Repair as necessary.

If the specified value was obtained

Checking activation

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

Using a diode test lamp connected to Battery positive, check the Engine Control Module (ECM) Power Supply Relay -J271- relay terminal 86 while cranking the engine (checking for ground signal from ECM).

The test lamp should be ON.

Switch the ignition OFF.

If the test lamp was ON

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

If the test lamp was Not ON

Using a multimeter, check the Engine Control Module (ECM) Power Supply Relay -J271- relay terminal 86, to the Engine Control Module (ECM) -J623- electrical harness connector T94 terminal 69 for resistance.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring and ground was not present from the ECM during crank

Replace the Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

SPEED SIGNAL, CHECKING

The following procedure requires a test drive. Observe all safety precautions. Refer to 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.

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, Short to Battery positive or to Ground.

Check the wiring connection for damage, corrosion, loose 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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

THREE WAY CATALYTIC CONVERTER, TWC 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 with front exhaust pipe.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

COMBINATION VALVE, CHECKING

The following procedure is used to test all combination valves.

Special tools and workshop equipment required

1. Hand vacuum pump.

Test conditions

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

Test procedure

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

Start procedure

Remove the vacuum hose from the combination valve.

Connect hand vacuum pump to combination valve vacuum connection.

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

Disconnect the Secondary Air Injection hose.

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

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

Operate the hand vacuum pump.

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.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

SECONDARY AIR INJECTION PUMP MOTOR, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

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

Test procedure

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

Start diagnosis

Note. The engine MUST be cold (room temperature) in order for the ECM to command the air pump relay ON. The pump runs for approximately 20 seconds. Once the engine has been started, the ECM will not command the pump to run again for approx 6-8 hrs. Due to potential damage to the catalyst, the generic scan tool has no provision for AIR relay driver control.

Checking operation

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

Using a jumper, connect Secondary Air Injection (SAI) Pump Relay --J299- - socket 30 to socket 87.

The AIR pump should be running.

If the pump does Not operate when using a jumper at the relay

Connect a test lamp between terminal 30 of the Secondary Air Injection (SAI) Pump Relay --J299- - socket and ground.

The test lamp should turn ON.

If the test lamp did Not turn ON, locate the open circuit between Secondary Air Injection (SAI) Pump Relay --J299- - socket 30 and Battery positive connection.

If the test lamp was ON

Disconnect the Secondary Air Injection (SAI) Pump Motor --V101-- connector -3-.

Scheme 100

Using a multimeter, check the Secondary Air Injection (SAI) Pump Motor --V101-- electrical harness connector terminal 2, (which passes through fuse 27 in Fuse Box B) to the Secondary Air Injection (SAI) Pump Relay --J299- - socket 87 for resistance. Refer to appropriate SYSTEM WIRING DIAGRAMS information.

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Check the circuit for an open, short or high resistance. If necessary, repair the faulty wiring or connection. Replace any open fuse.

If the specified value was obtained

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

Specified value: 1.5 ohms max.

If the specified value was Not obtained

Repair the open or high resistance in the ground circuit.

If the specified value was obtained

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

If the pump does operate when using a jumper at the relay

Install the SAI relay.

Connect a test lamp to terminal 86 of the Secondary Air Injection (SAI) Pump Relay --J299- -.

Turn the ignition On.

The test lamp should be ON.

Turn the ignition Off.

If the test lamp did Not turn on, locate the open circuit between the Secondary Air Injection (SAI) Pump Relay --J299- - and fuse 23 (Golf) or fuse 24 (EOS) of Fuse Panel B. Refer to appropriate SYSTEM WIRING DIAGRAMS information.

If the test lamp does turn ON, remove the Engine Control Module (ECM) -J623-.

Using a multimeter, check the SAI pump relay terminal 85 to the Engine Control Module (ECM) -J623- electrical harness connector T94 terminal 35 (Golf) or terminal 7 (EOS) for resistance or short. Refer to appropriate SYSTEM WIRING DIAGRAMS information.

Specified value: 1.5 ohms max.

If the specified value was not obtained, check for an open, high resistance or short and repair as necessary.

If the specified value was obtained, exchange the SAI relay with the ECM power supply relay located next to it.

Attempt to start the engine. If the engine does not start, replace the defective relay.

Switch the ignition Off.

If the engine does start, the ECM is not providing a ground to the SAI relay. Replace the Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

SECONDARY AIR INJECTION SOLENOID VALVE, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

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

Test procedure

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

Start diagnosis

Note. Voltage is supplied to the Secondary Air Injection (AIR) Solenoid Valve -N112- from fuse 24 in Fuse Box B.

Procedure

Disconnect the Secondary Air Injection (AIR) Solenoid Valve -N112- electrical harness connector -1-.

Scheme 101

Checking internal resistance

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

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

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

Switch the ignition ON.

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

Specified value: Battery voltage.

Switch the ignition OFF.

If the specified value was Not obtained

Check the wiring from the Secondary Air Injection (AIR) Solenoid Valve -N112- terminal 1 to fuse 20 in Fuse Panel B for a short circuit to Ground, or an open circuit.

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

If necessary, repair the wiring connection and replace fuse 20 in Fuse Panel B if blown.

If the specified value was obtained

Checking wiring

Remove the Engine Control Module (ECM) -J623-.

Using a multimeter --, check the Secondary Air Injection (AIR) Solenoid Valve -N112- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness connector T60 for an open circuit.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

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

Replace the Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

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 fuel filter OK.
3. The battery voltage at least 12.5 V.
4. All electrical consumers switched off (radiator fan must NOT run during test).
5. A/C switched off.
6. The fuel tank at least 1 / 4 filled.
7. The ignition switched Off.

Test procedure

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

Start diagnosis

Remove the engine cover.

Checking voltage

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

Switch the ignition On.

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

Switch the ignition Off.

If the specified value was obtained

Replace the Secondary Air Injection Sensor 1 -G609-.

If the specified value was Not obtained

Checking wiring connections

Remove the Engine Control Module (ECM) -J623-.

Using a multimeter, check the Secondary Air Injection Sensor 1 -G609- electrical harness connector terminals to the Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open circuit according to the appropriate system wiring diagram information.

Specified value: 1.5 ohms Max.

If the specified value was Not obtained

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

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

If necessary, repair the faulty wiring connection.

If the specified value was obtained and the voltage supply was Not OK

Replace the Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

CAMSHAFT POSITION SENSOR, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The 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

Remove the engine cover.

Disconnect the Camshaft Position (CMP) Sensor -G40- electrical harness connector -2-.

Scheme 102

Switch the ignition On.

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

Scheme 103

Specified value: near 5.0 V

Switch the ignition Off.

Checking wiring

Remove the Engine Control Module (ECM) -J623-.

Using a multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector to the Engine Control Module (ECM) electrical harness connector T60 for an open circuit or high resistance.

Scheme 104

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 positive or Ground.

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

If necessary, repair the faulty wiring connection.

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

Replace the Camshaft Position (CMP) Sensor -G40-.

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

Replace the Engine Control Module (ECM) -J623-.

Final procedures

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

1. Check the DTC memory «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code «READINESS CODE»(ref-475599-S18083240932012052300000) .

KNOCK SENSOR 1, CHECKING

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

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirements

1. The mounting bolt of Knock Sensor (KS) 1 -G61- 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

Remove the engine cover.

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-.

Scheme 105

Checking internal resistance

Using a multimeter, check the Knock Sensor terminals 1 to 2 for an internal short.

Specified value: infinity (Infinity) or OL reading.

If the specified value was Not obtained

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

If the specified value was obtained

Checking wiring

Remove the Engine Control Module (ECM) -J623-.

Using a multimeter, Check the Knock Sensor electrical harness connector to the Engine Control Module (ECM)J623 electrical harness connector T60 for an open circuit.

Scheme 106

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 positive or Ground.

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring and the resistance was OK

Replace the Engine Control Module (ECM) -J623-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

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

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

Test requirements

1. The Ignition Coils with Power Output Stage - N70, N127, N291, N292- fuses OK.
2. The Engine Control Module (ECM) Power Supply Relay -J271- OK.
3. The Engine Speed (RPM) Sensor -G28- OK.
4. The Camshaft Position (CMP) Sensor -G40- OK.
5. Battery voltage at least 12.5 volts.
6. All electrical consumers such as, lights and rear window defroster, switched off.
7. Vehicles with automatic transmission, shift selector lever into position "P" or "N".
8. A/C switched off.
9. Ground connections between engine/transmission/chassis OK.
10. Ignition switched Off.

Test procedure

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

Start diagnosis

Remove the engine cover.

Remove the Ignition Coils with Power Output Stage -N70, N127, N291, N292- electrical harness screws -1-.

Scheme 107

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

Scheme 108

Checking voltage supply

Switch the ignition On.

Using a multimeter, check the Ignition Coil electrical harness connector terminals 1 to ground for voltage.

Specified value: Battery voltage.

Switch the ignition Off.

If the specified value was Not obtained

Check the Ignition Coil electrical harness connector terminal 1 to fuse 14 in Fuse Box B for an open circuit.

If necessary, repair the faulty wiring connection, replace any open fuse.

If the specified value was obtained

Using a multimeter, check the Ignition Coil electrical harness connector terminals 1 to 2 and then 1 to 4 for voltage.

Specified value: Battery Voltage.

If the specified value was Not obtained

Check the wiring connection for an open circuit, high resistance or short circuit.

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

If necessary, repair the faulty wiring connection, replace any open fuse.

If the specified value was obtained

Checking activation

Disable the power supply to the Fuel Injectors -N30, N31, N32, N33- by removing injector fuse.

Using a 12 V 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-.

If the LED does not flicker

Checking wiring

Remove the Engine Control Module (ECM) -J623-.

Using a multimeter, Check the Ignition Coil electrical harness connector to the Engine Control Module (ECM)J623 electrical harness connector T60 for an open circuit. refer to the appropriate system wiring diagram information.

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 Engine Control Module (ECM) -J623-.

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 109

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

1. Check the DTC memory. Refer to «DIAGNOSTIC MODE 03 - READ DTC MEMORY»(ref-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

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) -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 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 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 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 T20 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, short circuit to Battery positive or Ground.

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring and the specified value was Not obtained

Replace the Engine Control Module (ECM) -J623-.

If the specified value was obtained

Checking wiring

Remove the Engine Control Module (ECM) -J623-.

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 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.

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 Data Bus On Board Diagnostic Interface -J533-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

CAN-BUS TERMINAL RESISTANCE, TCM TO ECM, 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. The Transmission Control Module (TCM) -J743- fuses 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.

Function

The Engine Control Module (ECM) -J623- communicates with the Transmission Control Module (TCM) -J743-.

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) -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 Engine Control Module (ECM) -J623-.

Test procedure

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

Start diagnosis

Raise the vehicle to gain access to the Transmission Control Module (TCM) -J743- electrical harness connector.

Disconnect the Transmission Control Module (TCM) -J743- electrical harness connector.

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

Using a multimeter, check the Transmission Control Module (TCM) -J743- electrical harness connector terminals 10 to 15 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, 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-.

If the specified value was obtained

Checking wiring

Remove the Engine Control Module (ECM) -J623-.

Using a multimeter, check the Transmission Control Module (TCM) -J743- electrical harness connector to the 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.

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 Selector Lever -E313-.

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .

LIN-BUS CIRCUIT, CHECKING

Special tools and workshop equipment required

1. Multimeter.
2. Wiring diagram.

Test requirement

1. A LIN 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) is connected to the Radiator Identification Sensor -G611- module by one LIN data Bus data wire. Radiator I.D. and a temperature signal are sent on the LIN bus to the ECM. If the information from the RIS module was not sent or cannot be read, the ECM will store a fault code.

Test procedure

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

Start diagnosis

Disconnect the Radiator Identification Sensor -G611- electrical harness connector.

Turn the ignition switch ON.

Using a multimeter, connect the red multimeter lead to terminal 3 of the Radiator Identification Sensor -G611- module connector and the black lead to ground.

Specified value: Battery voltage.

If the specified value was Not obtained

Check for an open or grounded circuit between terminal 3 and fuse SB 15.

Repair the circuit and replace the fuse if blown.

If the specified value was obtained

Connect the black multimeter lead to terminal 1 of the Radiator Identification Sensor -G611- harness connector and the red lead to Battery positive.

Specified value: Battery voltage.

If the specified value was Not obtained

Check for an open circuit or high resistance between Radiator Identification Sensor -G611- terminal 1 and the Engine Control Module (ECM) -J623- connector terminal 52.

Checking wiring

Disconnect the Engine Control Module (ECM) -J623- T94 electrical harness connector.

Disconnect the Radiator Identification Sensor -G611- module T3 electrical harness connector.

Using a multimeter, check the Engine Control Module (ECM) -J623- T94 electrical harness connector terminal 64 to the Radiator Identification Sensor -G611- module T3 electrical harness connector terminal 2 for resistance.

Specified value: 1.5 ohms max

If the specified value was Not obtained

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 Radiator Identification Sensor -G611- (radiator assembly).

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-475599-S21948744502012052300000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-475599-S19728113112012052300000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-475599-S18083240932012052300000) .