2.0L - Generic Scan Tool - Engine Code(s): Cjaa: Other Volkswagen Golf Mk7

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 appropriate 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 EPC system consists of the Throttle Valve Control Module (throttle body, throttle position sensor and motor in one unit), the ECM and Throttle Position/Accelerator Pedal position sensor. The EPC system contains multiple ECM inputs including traction control, cruise control and transmission shift control that contribute to recognizing, controlling and monitoring the position of the throttle valve by the ECM.

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

Operation of the throttle valve occurs via an electric motor in the throttle valve control module.

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

When an EPC fault is recognized by the ECM, the EPC lamp in the cluster illuminates and the system will default to limp in mode (limited control).

FUEL INJECTION SYSTEM

For all fuel injection system component locations, removal/installation procedures and torque specifications, refer to the appropriate Service Information.

ENGINE CONTROL MODULE

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

EXHAUST SYSTEM COMPONENTS

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

IGNITION SYSTEM

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

AUTOMATIC TRANSMISSION

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

For all automatic transmission component locations, removal/installation procedures and torque specifications, refer to the appropriate Service Information.

PRELIMINARY CHECK

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

Connect the scan tool.

Switch the ignition on.

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

If other DTCs are stored

Repair these DTCs first before performing the following procedure.

If no other DTCs are stored

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

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

If the DTC returns

Perform the diagnostic procedure.

If the DTC does not return

The fault is intermittent or a sporadic condition may exist.

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

If necessary, repair the faulty wiring connection.

Perform a road test to verify the repair.

If the DTC returns

Perform the diagnostic procedure.

If the DTC does not return

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

Generate readiness code. Refer to READINESS CODE .

READINESS CODE

Readiness Code Description

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

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

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

CHARGE PRESSURE ACTUATOR POSITION SENSOR

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

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 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.

Disconnect the Charge Pressure Actuator Position Sensor -G581- electrical harness connector.

Using a multimeter, check the Charge Pressure Actuator Position Sensor -G581- connector terminals 1 to 2 for resistance.

Specified Value: 6.30K ohms (+/- 300 ohms)

Using a multimeter, check the Charge Pressure Actuator Position Sensor -G581- connector terminals 2 to 3 for resistance.

Specified Value: 176 ohms (+/- 60 ohms)

If The Specified Value Was Not Obtained

Replace the Charge Pressure Actuator Position Sensor -G581- Refer to the Repair Information.

If The Specified Value Was Obtained

Checking Voltage

Disconnect the Charge Pressure Actuator Position Sensor -G581- electrical harness connector.

Turn ON the ignition switch.

Using a multimeter, check the Charge Pressure Actuator Position Sensor -G581- electrical harness connector terminals 2 to 3 for voltage.

Specified Value: Near 5 V

Switch the ignition off.

Proceed To Checking Wiring

Checking wiring

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

Using a multimeter, check the Charge Pressure Actuator Position Sensor -G581- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open circuit. Refer to Appropriate Wiring Diagrams for Pin locations.

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 Pressure Actuator Position Sensor -G581- Refer to the Repair information.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

CHARGE AIR PRESSURE SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Note. The Charge Air Pressure Sensor and IAT Sensor are combined and must be replaced as a unit. 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 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/IAT sensor -G31/G42- electrical harness connector.

Turn ON the ignition switch.

Using a multimeter, check the Charge Air Pressure Sensor/IAT sensor -G31/G42- electrical harness connector terminals 1 to 3 for voltage.

Specified Value: Near 5 V

Using a multimeter, check the Charge Air Pressure Sensor/IAT sensor -G31/G42- electrical harness connector terminals 1 to 4 for voltage.

Specified Value: Min. 4.40 V

Switch the ignition off.

If Either Specified Value Was Not Obtained

Checking Wiring

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

Using a multimeter, check the Charge Air Pressure Sensor/IAT sensor -G31/G42- 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. Refer to Appropriate Wiring Diagrams for Pin locations.

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/IAT sensor -G31/G42- Refer to the Repair information.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

CAMSHAFT POSITION SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

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 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.

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

Switch the ignition on.

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

Specified Value: Near 5.0 V

Using a multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector terminals 2 to 3 for voltage.

Specified Value: Near 4.90 V

Switch the ignition off.

If Any Specified Values Were Not Obtained

Checking wiring

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

Using a multimeter, Check the Camshaft Position (CMP) Sensor -G40- electrical harness connector to the Motronic Engine Control Module (ECM) electrical harness connector T60 for an open circuit. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 ohms Max.

If any specified values were Not obtained

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

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

If necessary, repair the faulty wiring connection.

If no malfunction is found in the wiring 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 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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

CAN BUS TERMINAL RESISTANCE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram

Test Requirement

1. A CAN bus malfunction was recognized
2. The module that does not communicate has ALL power and grounds present at the module connector. Refer to the Appropriate Wiring Diagrams for pin locations.
3. Battery voltage at least 12.5 volts
4. All electrical consumers switched off
5. Vehicles with automatic transmission, shift selector lever in park or neutral
6. A/C switched off
7. Ground connections between engine/transmission/chassis OK
8. Ignition switched Off

Test Procedure

Note. The engine control module must remain connected for the following step.

Disconnect the transmission control module electrical connector.

Using a multimeter, measure the resistance between the CAN bus low and CAN bus high from the transmission control module. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 50 To 69 ohms (At Approx. 20° C)

If the specified value was not obtained

Checking wiring

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

Using a multimeter, measure the resistance of the CAN bus low and CAN bus high circuits. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 ohms Max.

If the specification was not obtained

Check the wires for a short circuit to each other, a short to battery voltage, and a short to ground.

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

Repair as necessary.

If no malfunction is found in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

CAN BUS TO ABS CONTROL MODULE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram

Test Requirement

1. A CAN bus malfunction was recognized
2. The module that does not communicate has ALL power and grounds present at the module connector. Refer to the Appropriate Wiring Diagrams for pin locations.
3. Battery voltage at least 12.5 volts
4. All electrical consumers switched off
5. Vehicles with automatic transmission, shift selector lever in park or neutral
6. A/C switched off
7. Ground connections between engine/transmission/chassis OK
8. Ignition switched Off

Test Procedure

Note. The engine control module must remain connected for the following step.

Disconnect the Antilock Brake System -J104- electrical connector.

Using a multimeter, measure the resistance between the CAN bus low and CAN bus high at the Antilock Brake System -J104- harness connector (with ALL other modules connected). Refer to Appropriate Wiring Diagrams for Pin locations.

For Vehicles Without Electronic Stabilization Program (ESP)

For Vehicles With Electronic Stabilization Program (ESP)

Specified Value: 50 To 69 ohms (At Approx. 20° C)

If the specified value was not obtained

Checking wiring

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

Using a multimeter, measure the resistance of the CAN bus low and CAN bus high circuits. Refer to Appropriate Wiring Diagrams for location.

Specified Value: 1.5 ohms Max.

If the specification was not obtained

Check the wires for a short circuit to each other, a short to battery voltage, and a short to ground.

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

Repair as necessary.

If no malfunction is found in the wiring

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

CATALYTIC CONVERTER, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Special Tools And Workshop Equipment Required

1. Generic scan tool

Test Requirements

1. Battery voltage at least 12.5 volts
2. No leaks or damage to the exhaust system.
3. Oxygen sensors OK

Test Procedure

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

If the specified values are exceeded

Check the exhaust system for leaks.

Repair as necessary.

If no leaks are found in the exhaust system, no O2 sensor codes set and only DTC P0420 is set

Replace the catalyst. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

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.

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 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 Appropriate Wiring Diagrams for Pin locations.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

ENGINE COOLANT TEMPERATURE SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

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

Special Tools And Workshop Equipment Required

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

Test Requirements

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

Start Diagnosis

Engine must be at room temperature.

Connect the scan tool.

Switch the ignition On.

Using the scan tool, check the coolant temperature

If The Specified Value Was Obtained

Start the engine and let it run at idle.

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

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

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

Checking internal resistance

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

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

Use the chart below for the specified values

Specified Value

If the specified values were Not obtained

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

If the specified values were obtained

Checking wiring

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

Using a multimeter, check the Engine Coolant Temperature (ECT) Sensor - G62- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for a circuit fault. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified values: 1.5 ohms Max.

If the specified value was Not obtained

Check the wiring for an open, high resistance or short 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 sensor resistance 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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

ENGINE COOLANT TEMPERATURE SENSOR 2, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Note. Use only gold-plated terminals when servicing terminals in the electrical harness connector of Engine Coolant Temperature (ECT) Sensor 2 -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 cold.

Start Diagnosis

Engine must be at room temperature.

Connect the scan tool.

Switch the ignition On.

Using the scan tool, check the coolant temperature

If The Specified Value Was Obtained

Start the engine and let it run at idle.

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

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

Replace the Engine Coolant Temperature (ECT) Sensor 2 -G83-.

Checking internal resistance

Disconnect the Engine Coolant Temperature (ECT) Sensor 2 -G83- electrical harness connector (located on the lower radiator hose at the engine connection).

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

Use the chart below for the specified values

Specified Value

If The Specified Values Were Not Obtained

Replace the Engine Coolant Temperature (ECT) Sensor 2 -G83-.

If The Specified Values Were Obtained

Checking wiring

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

Using a multimeter, check the Engine Coolant Temperature (ECT) Sensor -G83- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T94 terminals for a circuit fault. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Values: 1.5 ohms Max.

If The Specified Value Was Not Obtained

Check the wiring for an open, high resistance or short 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 Sensor Resistance 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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

ENGINE SPEED SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

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 stall.

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 3 for resistance.

Specified Value: 1540 ohms +/- 300 Ohms

If The Specified Value Was Not Obtained

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

If The Specified Value Was Obtained

Checking wiring

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 Appropriate Wiring Diagrams for Pin locations.

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 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

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

EXHAUST FLAP CONTROL MODULE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Perform a preliminary check to verify the condition: PRELIMINARY CHECK .

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram.

Start Diagnosis

The Exhaust Flap Control Module -J883- is located near the center of the vehicle in the exhaust pipe.

Disconnect the Exhaust Flap Control Module -J883- electrical harness connector.

Checking Voltage

Switch the ignition On.

Using a multimeter, measure voltage supply between connector terminals 1 to 3 for voltage.

Specified Value: Near 5 V.

Using a multimeter, measure voltage supply between connector terminals 2 to 3 for voltage.

Specified Value: Near 5 V.

If Any Specified Value Was Not Obtained

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

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

If necessary, repair the faulty wiring connection.

If The Specified Values Were Obtained

Using a multimeter, measure voltage supply between connector terminals 4 to 5 for voltage.

Specified Value: Near 4.35 V.

Switch the ignition Off.

If The Specified Value Was Not Obtained

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

Check the wiring connections 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 Readings Were Correct

Replace the Exhaust Flap Control Module -J883-. Refer to the appropriate Service Information for removal and installation procedures.

If No Malfunction Is Detected In The Wiring And The Voltage Readings Were Not Correct

Checking wiring

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

Using a multimeter, check the Exhaust Flap Control Module -J883- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness T60 connector for resistance. Refer to Appropriate Wiring Diagrams for Pin locations.

For 2010 Models

For 2011 Models

Specified Value: 1.5 ohms Max.

If The Specified Value Was Not Obtained

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

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 Readings Were Not Correct

Replace the Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

FUEL INJECTORS, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

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

Special Tools And Workshop Equipment Required

1. Multimeter.
2. Wiring diagram.

Test Requirements

1. The Engine Speed (RPM) Sensor -G28- 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.

Start Diagnosis

Remove the engine cover.

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

Checking internal resistance

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

Specified Value: 178 K To 184 K ohms (At Approx. 20° C)

If The Specified Value Was Not Obtained

Replace the malfunctioning Fuel Injector --.

If The Specified Value Was Obtained

Checking wiring

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

Using a multimeter, check the Fuel Injector -- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for a short to ground or voltage, high resistance or an open circuit. Refer to Appropriate Wiring Diagrams for Pin locations.

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 or voltage.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

EXHAUST PRESSURE SENSOR 1 OR 2, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram

Test Requirements

1. The engine control module fuses OK
2. The battery voltage at least 12.5 V
3. All electrical consumers switched off
4. Engine MUST be at room temperature.
5. The ignition switched Off

Test Procedure

Make sure the engine is at room temperature.

Disconnect the Exhaust Pressure Sensor -G450/G451- electrical harness connector.

Checking internal resistance

Using a multimeter, measure the resistance between the terminals 1 and 2 of the Exhaust Pressure Sensor -G450/G451-.

Specified value for G450 (sensor 1): 6880 ohms (+/- 500 ohms)

Specified value for G451 (sensor 2): 69.7K ohms (+/- 1000 ohms)

Using a multimeter, measure the resistance between the terminals 2 and 3 of the Exhaust Pressure Sensor -G450/G451-.

Specified value for G450 (sensor 1): 4028 ohms (+/- 300 ohms)

Specified value for G451 (sensor 2): 9720 ohms (+/- 300 ohms)

If any specified value was not obtained

Replace the Exhaust Pressure Sensor -G450/G451-.

If the specified value was obtained

Checking the power supply

Switch the ignition ON.

Using a multimeter, measure the voltage of the Exhaust Pressure Sensor -G450/G451- harness connector terminal 1 to ground.

Specified value: near 5.01 V.

Using a multimeter, measure the voltage of the Exhaust Pressure Sensor -G450/G451- harness connector terminal 3 to ground.

Specified value: near 5.77 V.

Using a multimeter, measure the voltage of the Exhaust Pressure Sensor -G450/G451- harness connector terminal 2 to Battery Positive.

Specified value: Battery voltage.

Switch the ignition OFF.

If any of the specified values were Not obtained

Checking wiring

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

Using a multimeter, check the Exhaust Pressure Sensor -G450- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness T60 connector for resistance. Refer to Appropriate Wiring Diagram information for Pin locations.

Specified Value: 1.5 ohms Max.

If The Specified Value Was Not Obtained

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

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 Readings Were Not Correct

Replace the Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

FUEL PRESSURE SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter.
2. Wiring diagram.

Test Requirements

1. The Motronic 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 Fuel Pressure Sensor -G247- electrical harness connector.

Switch the ignition On.

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

Switch the ignition Off.

If The Specified Value Was Obtained

Replace the Fuel Pressure Sensor -G247- : Refer to the Repair information.

If the specified value was Not obtained

Checking Wiring

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

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. Refer to Appropriate Wiring Diagrams for Pin locations.

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

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

AUXILIARY FUEL PUMP CHECKING

Special Tools And Workshop Equipment Required

1. Multimeter.
2. Electrical connector test lead set.

Test Conditions

1. Battery voltage 12.5 V.
2. Fuse 27 in Fuse Panel C is OK.
3. Fuel filter OK.
4. Ignition switched off.

Test Procedure

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

Start Diagnosis

Disconnect the electrical harness connector from the Auxiliary Fuel Pump -V393- (right side of engine)

Connect a multimeter to both terminals of the Auxiliary Fuel Pump -V393- connector and check the motor resistance.

Specified Value: 1.4 Ohm (+/-.5 Ohm).

If the Specified value was Not obtained, replace the Auxiliary Fuel Pump -V393

If the Specified value was obtained

Remove the Fuel Pump Relay -J49- (under dash, left side)

Turn the ignition ON.

Using a test lamp connected to ground, touch terminal 30 of the Fuel Pump Relay -J49-.

The test lamp should be ON.

Using a test lamp connected to ground, touch terminal 86 of the Fuel Pump Relay -J49-.

The test lamp should be ON.

If the test lamp was Not ON for any above test

Check the circuit between the Fuel Pump Relay -J49- terminal 30 to fuse 27 in Fuse Box C, or Fuel Pump Relay -J49- terminal 86 to fuse 15 in Fuse Box B for an open, short to ground or high resistance. Refer to Appropriate Wiring Diagrams for fuse locations.

If the test lamp was ON for both tests

Turn the ignition OFF.

Install a jumper from relay terminal 30 to relay terminal 87.

Turn the ignition ON.

The Auxiliary Fuel Pump -V393- should operate.

If the Auxiliary Fuel Pump -V393- does operate

Replace the Fuel Pump Relay -J49- and retest for operation.

If the Auxiliary Fuel Pump -V393- still does Not operate

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

Check the resistance of the circuit from relay terminal 85 to the Motronic Engine Control Module (ECM) -J623- T60/15 terminal.

Specified value: 1.5 Ohm or less.

If the specified value was not obtained, repair the circuit between the relay and the ECM for an open, high resistance or short. Refer to Appropriate Wiring Diagrams for circuit locations.

If the specified value was obtained, replace the Motronic Engine Control Module (ECM) -J623-. Refer to the Repair information for removal instructions.

If the Auxiliary Fuel Pump -V393- did Not operate with the jumper connected

Leave ignition ON and jumper connected.

Connect a test lamp to ground and touch terminal 2 of the Auxiliary Fuel Pump -V393- electrical harness connector.

The test lamp should be ON.

If the test lamp is Not ON, check for an open circuit between the relay terminal 87 and the Auxiliary Fuel Pump -V393- harness connector terminal 2 for an open or high resistance. Repair as necessary. Refer to Appropriate Wiring Diagrams for circuit locations.

If the test lamp is ON, remove the test lamp from engine ground and connect it to terminal 1 of the Auxiliary Fuel Pump -V393- connector. Touch the other end of the test lamp to terminal 2.

The test lamp should be ON.

If the test lamp is Not ON, check for an open circuit between the Auxiliary Fuel Pump -V393- harness connector terminal 1 to ground for an open or high resistance. Repair as necessary. Refer to Appropriate Wiring Diagrams for circuit locations.

If the test lamp was ON, replace the Auxiliary Fuel Pump -V393-.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

EGR TEMPERATURE SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Perform a preliminary check to verify the condition: PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Electrical connector test lead set

Test Conditions

1. Battery voltage 12.5 V
2. Fuse OK
3. Engine MUST be at room temperature.
4. Ignition switched Off

Test Procedure

Engine MUST be at room temperature.

Disconnect the EGR Temperature Sensor -G98- connector.

Using a multimeter, check the EGR Temperature Sensor -G98- terminals 1 to 2 for resistance.

Specified Value: 6.96 K ohms (+/- 400 ohms) At Room Temperature.

If the specified value was Not obtained

Replace the EGR Temperature Sensor -G98

If the specified value was obtained

Turn the ignition switch ON.

Using a multimeter, check the EGR Temperature Sensor -G98- terminals 1 to 2 for voltage.

Specified Value: 3.32 V (+/-.4 V)

If the specified value was Not obtained

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

Using a multimeter, check the EGR Temperature Sensor -G98- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminals for an open circuit. Refer to Appropriate Wiring Diagrams for Pin locations.

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 there was no fault found in the wiring and the voltage was Not obtained

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

EGR VALVE 2 WITH POSITION SENSOR

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Perform a preliminary check to verify the condition: PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Note. The EGR Valve 2 and Low Pressure EGR Valve both refer to the same component (N213) and for 2011 Models, it is referred to a V339 EGR Motor 2. Name changes occur in Appropriate Wiring Diagrams, parts listings etc. The EGR Position Sensor (Potentiometer) is part of the N213 or V339 valve assembly and is serviced as one component.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Electrical connector test lead set

Test Conditions

1. Fuse OK
2. Battery voltage 12.5 V
3. Ignition switched off

Start Diagnosis

Disconnect the EGR 2/Potentiometer -N213 or V339- electrical harness connector.

Checking internal resistance

Using a multimeter, check the EGR 2/Potentiometer -N213 or V339- terminals 2 and 6 for resistance.

Specified Value: 5.6 ohms (+/- 1 Ohm)

Using a multimeter, check the EGR 2/Potentiometer -N213 or V339- terminals 1 and 5 for resistance.

Specified Value: 175.5 ohms (+/- 40 Ohms).

If Any Of The Specified Values Are Not Obtained

Replace the EGR 2/Potentiometer -N213 or V339-.

If The Specification Is Obtained

Checking Voltage

Switch the ignition On.

Using a multimeter, check the EGR 2/Potentiometer -N213 or V339- electrical harness connector terminal 2 to Ground for voltage.

Using a multimeter, check the EGR 2/Potentiometer -N213 or V339- electrical harness connector terminal 6 to Ground for voltage.

Switch the ignition Off.

Specified Value For Each Test: Battery Voltage.

If The Specified Value Was Not Obtained

Check the EGR 2/Potentiometer -N213 or V339- electrical harness terminal 2 or 6 for an for an open circuit, high resistance or a short circuit. Refer to Appropriate Wiring Diagrams for Pin/circuit locations.

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

If necessary, repair the faulty wiring connection.

If The Specified Value Was Obtained

Checking wiring

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

Using a multimeter, check the EGR 2/Potentiometer -N213 or V339- electrical harness connector terminal to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminal for resistance. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 ohms Max.

If The Specification Was Not Obtained

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

If necessary, repair the faulty wiring connection.

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

If No Malfunction Is Detected In The Wiring And The Voltage 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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

EGR VACUUM REGULATOR SOLENOID VALVE WITH POTENTIOMETER, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Perform a preliminary check to verify the condition: PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Note. The EGR Vacuum Regulator Solenoid Valve and High Pressure EGR Valve both refer to the same component N18 or V338. Name changes occur in Appropriate Wiring Diagrams, parts listings etc. The EGR potentiometer G212 is part of the N18 or V338 valve assembly and is serviced as one component.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Electrical connector test lead set

Test Conditions

1. Fuse OK
2. Battery voltage 12.5 V
3. Ignition switched off

Start Diagnosis

Disconnect the EGR/Potentiometer -N18/V338 - electrical harness connector. Refer to Appropriate Wiring Diagrams for Pin locations.

Checking Internal Resistance

Using a multimeter, check the EGR/Potentiometer -N18/V338 - terminals 2 to 6 for resistance.

Specified Value: 18.5 ohms (+/- 1.3 Ohms).

Using a multimeter, check the EGR/Potentiometer -N18/V338 - terminals 1 to 5 for resistance.

Specified Value: 175.6 ohms (+/- 20 Ohms).

If Any Of The Specified Values Are Not Obtained

Replace the EGR/Potentiometer -N18/V338 -.

If The Specifications Were Obtained

Checking Voltage

Switch the ignition On.

Using a multimeter, check the EGR/Potentiometer -N18/V338 - electrical harness connector terminal 2 to Ground for voltage.

Using a multimeter, check the EGR/Potentiometer -N18/V338 - electrical harness connector terminal 6 to Ground for voltage.

Using a multimeter, check the EGR/Potentiometer -N18/V338 - electrical harness connector terminal 3 to Battery Positive (+) for voltage.

Specified Value For Above Tests: Near Battery Voltage.

Using a multimeter, check the EGR/Potentiometer -N18/V338 - electrical harness connector terminal 1 to Ground for voltage.

Switch the ignition Off.

Specified Value: Near 5.01 V

If Any Of The Specified Values Were Not Obtained

Check the EGR/Potentiometer -N18/V338 - electrical harness to the Motronic Engine Control Module (ECM) -J623- for an for an open circuit or a short circuit. Refer to Appropriate Wiring Diagrams for Pin locations.

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

If necessary, repair the faulty wiring connection.

If The Specified Value Was Obtained

Checking wiring

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

Using a multimeter, check the EGR/Potentiometer -N18/V338 - electrical harness connector terminal to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminal for resistance. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 ohms Max.

If The Specification Was Not Obtained

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

If necessary, repair the faulty wiring connection.

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

If No Malfunction Is Detected In The Wiring And The Voltage 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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

EXHAUST GAS TEMPERATURE SENSOR 1 - 4, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Perform a preliminary check to verify the condition: PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Electrical connector test lead set

Test Conditions

1. Battery voltage 12.5 V
2. Fuse OK
3. Ignition switched off

Note. The engine MUST be at room temperature to read the resistance of the Exhaust Gas Temperature Sensor. Exhaust system must be cool to touch.

Test Procedure

Disconnect the Exhaust Gas Temperature Sensor -- harness connector.

Measure the resistance of the 2 terminals of the Exhaust Gas Temperature Sensor -- connector.

Specified Value: 215 Ohms (+/- 25 Ohm).

If The Specified Value Was Not Obtained

Replace the Exhaust Gas Temperature Sensor --.

If The Specified Value Was Obtained

Connect the voltmeter to terminal 1 of the Exhaust Gas Temperature Sensor -- harness connector and ground black lead to engine.

Turn the ignition switch ON.

Specified Value: 3.35 V (+/-.5 V).

If The Specified Value Was Obtained

Leave the red lead on terminal 1 and connect the black lead to terminal 2.

Specified Value: 3.35 V (+/-.5 V).

Turn the ignition switch Off.

If Any Of The Specified Values Were Not Obtained

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

Using a multimeter, check the Exhaust Gas Temperature Sensor -- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T94 connector for resistance. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 Ohms Max.

If Any Of The Specified Values Were Not Obtained

Check the wires for a short circuit to each other, a short to battery voltage, or a short to ground.

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

Repair as necessary.

If No Malfunction Is Detected In Electrical Circuit

Replace the Motronic Engine Control Module (ECM) -J623-. Refer to the Repair information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

FUEL TEMPERATURE SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram

Test Requirements

1. The engine control module fuses OK
2. Battery voltage at least 12.5 volts
3. All electrical consumers switched off
4. Vehicles with automatic transmission, shift selector lever in park or neutral
5. A/C switched off
6. Ground connections between engine/transmission/chassis OK

Test Procedure

Disconnect the Fuel Temperature Sensor -G81- electrical harness connector.

Checking internal resistance

Using a multimeter, measure the resistance between the terminals of the Fuel Temperature Sensor -G81-.

Use The Chart Below To Estimate The Specified Values

If The Sensor Value Was Not Within The Specified Range

Replace the Fuel Temperature Sensor -G81-.

Checking the voltage

Disconnect the Fuel Temperature Sensor -G81- connector.

Turn the ignition switch ON.

Using a multimeter, measure the voltage between the Fuel Temperature Sensor -G81- terminal 2 and ground.

Specified Value: Near 5.0 V

If The Specification Was Obtained

Using a multimeter, measure the voltage between the Fuel Temperature Sensor -G81- terminals 2 and 1.

Specified Value: Near 5.0 V

If The Voltages Above Were Not Obtained

Checking the wiring

Remove the Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

Using a multimeter, measure the resistance of circuits between the Fuel Temperature Sensor -G81- and the Engine Control Module (ECM) -J623- electrical harness connectors. Refer to the applicable wiring diagram. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 ohms Max.

If The Specification Was Not Obtained

Check the wires for high resistance, a short circuit to each other, a short to battery voltage, and a short to ground.

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

Repair as necessary.

If No Malfunction Is Detected In The Sensor Or Wiring

Replace the Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

CYLINDER PRESSURE SENSOR CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

The Cylinder Pressure Sensor is located within the Glow Plug and is not serviceable separately.

Note. The Glow plug terminal/connector is not repairable. The harness must be replaced if damaged.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter.
2. Wiring diagram.

Test Requirements

1. Battery voltage at least 12.5 volts.
2. Ground connections between engine/transmission/chassis OK.
3. Ignition switched off.

Start Diagnosis

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

Using a multimeter, check the following Engine Control Module (ECM) -J623- circuits for resistance with the Cylinder Internal Pressure Sensor -- (glow plug) connected. Connect the RED ohm meter lead to T60/36. Connect the BLACK ohm meter lead to the corresponding sensor terminal listed in the chart below. Refer to Appropriate Wiring Diagrams for Pin locations.

Note. Polarity of the ohm meter leads MUST be correct or an error in the readings will occur leading to misdiagnosis.

Specified Values: 4.0 Mohms. (+/-.5 Mohms)

If The Specified Value Was Not Obtained

Switch the Glow Plug with the faulty reading to a Glow plug that has a correct reading, reinstall in engine and retest for resistance on the circuit. If reading is now in range, replace the faulty Glow Plug. If the reading is still out of range, the harness will have to be replaced.

If The Specified Values In The Above Tests Were Obtained

Replace the Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

AUTOMATIC GLOW TIME MODULE AND GLOW PLUG CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram

Test Requirements

1. A/C switched off
2. All electrical consumers switched off
3. Battery voltage at least 12.5 volts
4. Engine control module fuses OK
5. Ground connections between engine/transmission/chassis OK
6. Ignition switched off
7. Vehicles with automatic transmission, shift selector lever in park or neutral

Start Diagnosis

The Automatic Glow Time Control Module -J179- is a relay located on the bottom of the underhood fuse box and can be viewed by removing the battery to access the underside of the fuse box and remove the automatic glow time control module (relay) which is held in place by 1 mounting screw (2010 Models).

Disconnect the Automatic Glow Time Control Module -J179- (relay) connector.

Checking Voltage

Ignition switched ON.

Using a multimeter with BLACK lead connected to engine ground, measure the voltage of terminal 30 (T11-11) and then 87 (T11-6) of the Automatic Glow Time Control Module -J179- green (relay) connector. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified values: Battery voltage.

If The Specified Value Was Obtained

Using a multimeter with the RED lead connected to Battery Positive, measure the ground of terminal 31 (T11-7) of the Automatic Glow Time Control Module -J179- green (relay) connector.

Specified Value: Battery Voltage.

Ignition switched OFF.

If The Any Of The Specified Values Were Not Obtained

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

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

Replace any blown fuses.

Repair as necessary.

If The Specified Value Was Obtained

Ignition switched ON.

Using a multimeter with BLACK lead connected to engine ground, measure the voltage at the terminal marked ST (T11-10) of the Automatic Glow Time Control Module -J179- green (relay) connector. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 3.44 V (+/-.5 V)

If The Specified Value Was Obtained

Using a multimeter with BLACK lead connected to engine ground, measure the voltage at the terminal marked D1 (T11-9) of the Automatic Glow Time Control Module -J179- green (relay) connector.

Specified Value: 11.44 V (+/-.8 V)

If The Voltage Readings Were Correct

Ignition switched OFF.

Replace the Automatic Glow Time Control Module -J179- (relay).

If Any Of The Specified Values Were Not Obtained

Checking wiring

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

Using a multimeter, check the Automatic Glow Time Control Module -J179- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness T60 connector for resistance. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 ohms Max.

If The Specification Was Not Obtained

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

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 Readings Were Not Correct

Replace the Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

Checking Glow Plugs

Using a multimeter, check the resistance of each glow plug at the Automatic Glow Time Control Module -J179- (relay) connector to engine ground (with the glow plugs connected). These are identified as G1 (T11-1), G2 (T11-2), G3 (T11-3), G4 (T11-4) on the connector and correspond to Glow plug 1, 2, 3, 4. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.3 ohms Max. Each Glow Plug (.7ohms For Glow Plug.3 ohms For Wiring).

If The Specified Value Was Not Obtained

Check the glow plug or circuit for a short to voltage, open circuit or high resistance.

Note. The Glow plug terminal/connector is not repairable. The harness must be replaced if damaged.

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

Repair as necessary.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

INTAKE AIR TEMPERATURE SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Note. The Charge Air Pressure Sensor and IAT Sensor are combined and must be replaced as a unit. Use only gold-plated terminals when servicing terminals in the electrical harness connector of the Charge Air Pressure Sensor/IAT sensor -G31/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

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 Charge Air Pressure Sensor/IAT sensor -G31/G42- electrical harness connector.

Using a multimeter, check the Charge Air Pressure Sensor/IAT sensor -G31/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 Charge Air Pressure Sensor/IAT sensor -G31/G42- Refer to the Repair information.

If The Specified Value Was Obtained

Turn the ignition switch ON

Check the voltage from terminal 1 to terminal 2 of the IAT connector.

Specified value: Min. 4.40 V

If The Specified Value Was Not Obtained

Checking Wiring

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

Using a multimeter, check the Charge Air Pressure Sensor/IAT sensor -G31/G42- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness T94 connector for resistance. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 ohms Max.

If The Specification Was Not Obtained

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

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 Readings Were Not Correct

Replace the Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

INTAKE MANIFOLD FLAP MOTOR AND RUNNER POSITION SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter.
2. Wiring diagram.

Test Requirements

1. The ignition switched Off.

Start Diagnosis

Disconnect the Intake Flap Motor -V157- electrical harness connector.

Checking Voltage

Switch the ignition On.

Using a multimeter, measure voltage supply between connector terminals 1 to 3 for voltage. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: Approx. 5 V.

If The Specified Value Was Not Obtained

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

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

If necessary, repair the faulty wiring connection.

If The Specified Value Was Obtained

Ignition still On.

Using a multimeter, measure voltage supply between connector terminals 4 to 5 for voltage.

Specified Value: Near 4.35 V.

If The Specified Value Was Not Obtained

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

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

If necessary, repair the faulty wiring connection.

If The Specified Value Was Obtained

Using a multimeter, measure voltage supply between connector terminals 2 to 3 for voltage.

Switch the ignition Off.

Specified Value: Approx. 5.01 V.

If The Specified Value Was Not Obtained

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

Check the wiring connections 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 Readings Were Correct

Replace the Intake Flap Motor -V157-. Refer to the appropriate Service Information for removal and installation procedures.

If No Malfunction Is Detected In The Wiring And The Voltage Readings Were Not Correct

Checking wiring

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

Using a multimeter, check the Intake Flap Motor -V157- electrical harness connector to the Engine Control Module (ECM) -J623- electrical harness T60 connector for resistance. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 ohms Max.

If The Specification Was Not Obtained

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

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 Readings Were Not Correct

Replace the Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

FUEL PRESSURE REGULATOR VALVE CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram

Test Requirements

1. The Engine Speed (RPM) Sensor -G28- 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.

Start Diagnosis

Remove the engine cover.

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

Checking internal resistance

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

Specified Value: Near 4.1 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

Turn the ignition switch ON.

Connect a multimeter red lead to terminal 2 of the Fuel Pressure Regulator Valve -N276- and the other meter lead to ground and measure the voltage. Refer to Appropriate Wiring Diagrams for Pin locations.

Turn the ignition switch OFF.

Specified Value: Battery Voltage.

If The Specified Value Was Not Obtained

Check the circuit between terminal 2 of the Fuel Pressure Regulator Valve -N276- and fuse 14 in Fuse Panel B for an open, short or high resistance.

Repair as necessary.

If The Specified Value Was Obtained

Turn the ignition switch ON.

Connect a multimeter red lead to terminal 1 of the Fuel Pressure Regulator Valve -N276- and the other meter lead to ground.

Specified Value: Near 3.40 V.

Turn the ignition switch OFF.

If The Specified Value Was Not Obtained

Checking wiring

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

Using a multimeter, check the Fuel Pressure Regulator Valve -N276- electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 45 terminal for a short to ground or voltage, high resistance or an open circuit. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 ohms Max.

If The Specification Is Not Obtained

Check the wires for a short circuit to each other, a short to battery voltage, and a short to ground.

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

Repair as necessary.

If No Malfunction Is Detected In The Wiring And The Voltage Was Not Correct

Replace the Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

FUEL PRESSURE METERING VALVE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram

Test Requirements

1. The Engine Speed (RPM) Sensor -G28- 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.

Start Diagnosis

Remove the engine cover.

Disconnect the Fuel Pressure Metering Valve -N290- electrical harness connector.

Checking internal resistance

Using a multimeter, check the Fuel Pressure Metering Valve -N290- terminals 1 to 2 for resistance.

Specified value: Near 3.2 ohms (+/- 1 ohm)

If The Specified Value Was Not Obtained

Replace the Fuel Pressure Metering Valve -N290-.

If The Specified Value Was Obtained

Turn the ignition switch ON.

Connect a multimeter red lead to terminal 2 of the Fuel Pressure Metering Valve -N290- and the black meter lead to ground and measure the voltage.

Turn the ignition switch OFF.

Specified Value: Battery Voltage.

If The Specified Value Was Not Obtained

Check the circuit between terminal 2 of the Fuel Pressure Metering Valve -N290- and fuse 14 (2010 Models) or fuse 7 (2011 Models) in Fuse Panel B for an open, short or high resistance. Refer to Appropriate Wiring Diagrams for Pin/fuse locations.

Repair as necessary.

If The Specified Value Was Obtained

Turn the ignition switch ON.

Connect a multimeter red lead to terminal 1 of the Fuel Pressure Metering Valve -N290- and the black meter lead to ground.

Specified Value: Near 3.2 V (+/-.5 V).

Turn the ignition switch OFF.

If The Specified Value Was Not Obtained

Checking wiring

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

Using a multimeter, check the Fuel Pressure Metering Valve -N290- electrical harness connector terminal 1 to the Motronic Engine Control Module (ECM) -J623- electrical harness connector T60 terminal 60 for a short to ground or voltage, high resistance or an open circuit. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 ohms Max.

If The Specification Is Not Obtained

Check the wires for a short circuit to each other, a short to battery voltage, and a short to ground.

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

Repair as necessary.

If No Malfunction Is Detected In The Wiring And The Voltage Was Not Correct

Replace the Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

MASS AIR FLOW SENSOR, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

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 55° 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 The Specified Value Was Obtained: Condition Is Not Present At This Time.

Check the electrical harness connector at the ECM and sensor for damage, corrosion, loose or broken terminals.

Check the intake duct for air leaks, loose connections.

If The Specified Value Was Not Obtained

Checking voltage supply

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

Start the engine and let it run at idle.

Using a multimeter, check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminal 5 to engine Ground for voltage.

Specified Value: Battery Voltage.

Switch the ignition OFF.

If the specified value was Not obtained

Remove fuse 1 (2010 Models) or fuse 15 (2011 Models) in Fuse Panel C. Refer to Appropriate Wiring Diagrams for fuse locations. Check the Mass Air Flow (MAF) Sensor -G70- electrical harness connector terminal 5 to Fuse 1 or 15 in Fuse Panel C for an open circuit, high resistance or short to ground.

Specified Value: 1.5 ohms Max.

If necessary, repair the faulty wiring connection.

If The Specified Value Was Obtained

Checking electrical circuit

Start the engine and let it run at idle.

Using a multimeter, connect black lead to ground and red lead to terminal 1, 2 and 4 of the MAF connector and check for voltage using the chart below.

Specified Values

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 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. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Value: 1.5 ohms Max.

If The Specified Value Was Not Obtained

Check the wiring for an open, high resistance or short 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 Mass Air Flow (MAF) Sensor -G70- Refer to the Repair information.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

OXYGEN SENSOR BEFORE CATALYTIC CONVERTER, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

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. Fuse for Heated Oxygen Sensor (HO2S) -G39- OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. A/C switched off.
5. Ground connections between engine/transmission/chassis OK.
6. Exhaust system between catalytic converter and cylinder head properly sealed.

Function Test

Connect the scan tool.

Start engine and let it run at idle.

Select Diagnostic mode 6.

Select "Test-ID 01: Heated Oxygen Sensor". Refer to test: Monitor-ID $01: Oxygen Sensor Monitor Bank 1 - Sensor 1 Monitor-ID $01: Oxygen Sensor Monitor Bank 1 - Sensor 1 .

Switch ignition Off.

If The Monitor Failed

Checking Heater Resistance

Disconnect the Heated Oxygen Sensor (HO2S) --G39-- electrical harness connector at the engine bulkhead (left side).

Using a multimeter, measure the resistance of the heater from terminal 3 to terminal 4 of the Heated Oxygen Sensor (HO2S) --G39-- connector.

Specified Value: 2 - 4 ohms With The Exhaust System At Room Temperature

If The Specified Value Was Not Obtained

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

If The Specified Value Was Obtained

Checking heater voltage

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

Switch ignition On.

Using a multimeter, measure the voltage from terminal 4 of the Heated Oxygen Sensor (HO2S) --G39-- harness connector to ground.

Specification: Near Battery Voltage

Switch ignition Off.

If Specified Value Is Not Obtained

Check for an open, short to ground or high resistance between terminal 4 of the Heated Oxygen Sensor (HO2S) --G39-- and fuse 21 (2010 Models) or fuse 4 (2011 Models) in Fuse Box B. Refer to Appropriate Wiring Diagrams for Pin/fuse locations.

If necessary, repair the wiring connection.

If The Specified Value Was Obtained

Checking HO2S voltage

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

Switch ignition On.

Using a multimeter, measure the voltage from terminal 3 of the Heated Oxygen Sensor (HO2S) --G39-- harness connector to ground. Refer to Appropriate Wiring Diagrams for all Pin locations.

Specification: Near 4.76 V

Using a multimeter, measure the voltage from terminal 1 of the Heated Oxygen Sensor (HO2S) --G39-- harness connector to ground.

Specification: Near 2.85 V

Using a multimeter, measure the voltage from terminal 5 of the Heated Oxygen Sensor (HO2S) --G39-- harness connector to ground.

Specification: Near 2.85 V

Using a multimeter, measure the voltage from terminal 2 of the Heated Oxygen Sensor (HO2S) --G39-- harness connector to ground.

Specification: Near 2.50 V

Using a multimeter, measure the voltage from terminal 6 of the Heated Oxygen Sensor (HO2S) --G39-- harness connector to ground.

Specification: Near 2.93 V

Switch ignition Off.

If Any Of The Specified Values Were Not Obtained

Checking wiring

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) --G39-- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical connector T94 for an open circuit. Refer to Appropriate Wiring Diagrams for Pin locations.

Specified Resistance 1.5 ohms Max.

If The Specification Is Not Obtained

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

If necessary, repair the wiring connection.

If No Malfunctions Are Found In Wiring And The Voltage 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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

OXYGEN SENSOR BEHIND CATALYTIC CONVERTER, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Note. When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S) --G130--, use only gold-plated terminals.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram

Test Requirements

1. Fuse for Heated Oxygen Sensor (HO2S) --G130-- OK.
2. Battery voltage at least 12.5 volts.
3. All electrical consumers such as, lights and rear window defroster, switched off.
4. A/C switched off.
5. Ground connections between engine/transmission/chassis OK.
6. Exhaust system properly sealed.

Function Test

Connect the scan tool.

Start engine and let it run at idle.

Select Diagnostic mode 6.

Select "Test-ID 01: Heated Oxygen Sensor". Refer to test: Monitor-ID $02: Oxygen Sensor Monitor Bank 1- Sensor 2 .

Switch ignition Off.

If The Monitor Failed

Checking heater resistance

Disconnect the Heated Oxygen Sensor (HO2S) --G130-- electrical harness connector -3- located on undercarriage left side frame rail.

Using a multimeter, measure the resistance from terminal 3 to terminal 4 of the Heated Oxygen Sensor (HO2S) --G130-- connector.

Specified Value: 2 - 4 ohms With The Exhaust System At Room Temperature

If The Specified Value Was Not Obtained

Replace the Heated Oxygen Sensor (HO2S) --G130--.

If The Specified Value Was Obtained

Checking heater voltage

Disconnect the Heated Oxygen Sensor (HO2S) --G130-- electrical harness connector.

Switch ignition On.

Using a multimeter, measure the voltage from terminal 4 of the Heated Oxygen Sensor (HO2S) --G130-- harness connector to ground.

Specification: Near Battery Voltage

Switch ignition Off.

If Specified Value Is Not Obtained

Check for an open, short to ground or high resistance between terminal 4 of the Heated Oxygen Sensor (HO2S) --G130-- and fuse 21 (2010 Models) or fuse 4 (2011 Models) in Fuse Box B. Refer to Appropriate Wiring Diagrams for fuse locations.

If necessary, repair the wiring connection.

If The Specified Value Was Obtained

Checking HO2S voltage

Disconnect the Heated Oxygen Sensor (HO2S) --G130-- electrical harness connector.

Switch ignition on.

Using a multimeter, measure the voltage from terminal 3 of the Heated Oxygen Sensor (HO2S) --G130-- harness connector to ground.

Specification: Near 4.76 V

Using a multimeter, measure the voltage from terminal 1 of the Heated Oxygen Sensor (HO2S) --G130-- harness connector to ground.

Specification: Near 2.85 V

Using a multimeter, measure the voltage from terminal 5 of the Heated Oxygen Sensor (HO2S) --G130-- harness connector to ground.

Specification: Near 2.85 V

Using a multimeter, measure the voltage from terminal 2 of the Heated Oxygen Sensor (HO2S) --G130-- harness connector to ground.

Specification: Near 2.50 V

Using a multimeter, measure the voltage from terminal 6 of the Heated Oxygen Sensor (HO2S) --G130-- harness connector to ground.

Specification: Near 2.93 V

Switch ignition off.

If Any Of The Specified Values Were Not Obtained

Checking Wiring

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

Using a multimeter, check the Heated Oxygen Sensor (HO2S) --G130-- electrical harness connector terminals to the Motronic Engine Control Module (ECM) -J623- electrical connector T94 for an open circuit. Refer to Appropriate Wiring Diagrams for pin locations.

Specified Resistance 1.5 ohms Max.

If The Specification Is Not Obtained

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

If necessary, repair the wiring connection.

If No Malfunctions Are Found In Wiring And The Voltage Was Not Ok

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

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

THROTTLE POSITION SENSOR/ACCELERATOR PEDAL POSITION SENSOR 2, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Perform a preliminary check to verify the condition: PRELIMINARY CHECK .

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 Throttle Position (TP) Sensor -G79- /Accelerator Pedal Position Sensor 2 -G185-.

Start Diagnosis

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

Checking Voltage Supply And Wiring

Switch the ignition ON.

Using a multimeter, check the following wiring connections for voltage. Refer to Appropriate Wiring Diagrams for pin locations.

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 Accelerator Pedal Position Sensor -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. Refer to Appropriate Wiring Diagrams for pin locations.

Specified Value: 1.5 ohms Max.

If The Specified Value Was Not Obtained

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

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

THROTTLE VALVE CONTROL MODULE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram

Test Requirements

1. The engine control module fuses OK
2. The battery voltage at least 12.5 V
3. All electrical consumers switched off
4. A/C switched off
5. The ignition switched off
6. Vehicles with automatic transmission, shift selector lever in park or neutral
7. Ground connections between engine/transmission/chassis OK
8. Throttle valve must not be damaged or dirty

Test Procedure

Connect the scan tool.

Switch ignition on.

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

Switch ignition Off.

If The Specified Values Are Not Obtained

Remove the throttle valve control module far enough so that the electrical connector can be reached.

Disconnect the throttle valve control module electrical connector.

Checking internal resistance

Note. The correct polarity of the ohm meter leads MUST be maintained or the results of the Throttle Valve Control Module diagnosis will be incorrect. Refer to Appropriate Wiring Diagrams for pin locations.

Using a multimeter, connect the Black lead to terminal 1 and the Red lead to terminal 2 of the Throttle Valve Control Module -J338-.

Measure the internal resistance of the throttle valve control module.

Specified Value: 2.6 - 3.0 M ohms

Using a multimeter, connect the Black lead to terminal 4 and the Red lead to terminal 3 of the Throttle Valve Control Module -J338-.

Specified Value: 10.8 - 12.9 M ohms

If Any Of The Specified Values Were Not Obtained Or The Valve Is Binding Or Sticking

Replace the Throttle Valve Control Module -J338-.

If The Specified Values Were Obtained

Checking Voltage supply and wiring

Switch the ignition On.

Using a multimeter, measure the voltage between terminal 1 and 2 of the Throttle Valve Control Module -J338- electrical harness connector.

Specified Value: 11.91 V (+/- 1.2 V)

Using a multimeter, measure the voltage between terminal 1 and 3 of the Throttle Valve Control Module -J338- electrical harness connector.

Specified Value: 3.47 V (+/- 1 V)

Using a multimeter, measure the voltage between terminal 1 and 4 of the Throttle Valve Control Module -J338- electrical harness connector.

Specified Value: 11.64 V (+/- 1.5 V)

If The Specification Was Not Obtained

Switch the ignition Off.

Using a multimeter, measure the resistance of the circuits between the throttle valve control module and the engine control module or specified location. Refer to Appropriate Wiring Diagrams for pin locations.

Specified Value: 1.5 ohms Max.

If The Specification Was Not Obtained

Check the wires for high resistance, a short circuit to battery voltage or short to ground.

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

Repair as necessary.

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 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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

WASTEGATE BYPASS REGULATOR VALVE, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

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.

Start Diagnosis

Remove the engine cover with air filter.

Checking internal resistance

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

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

Specified Value: 12 To 18 ohms (At Approx. 20° C)

If The Specified Value Was Not Obtained

Replace the Wastegate Bypass Regulator Valve -N75- Refer to the Repair information.

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.

Check fuse 23 (2010 Model) or fuse 5 (2011 Model) in Fuse Panel B for open and replace if blown. Refer to Appropriate Wiring Diagrams for fuse locations.

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

If necessary, repair the wiring connection.

If The Specified Value Was 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 Wastegate Bypass Regulator Valve -N75- electrical harness connector terminal to the Motronic Engine Control Module (ECM) -J623- electrical harness connector terminal 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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

SPEED SIGNAL, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Scan tool.
2. Wiring diagram.

Test Requirements

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

Function Test

Connect the scan tool.

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

Using the scan tool, Check the vehicle speed

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

Specified Value: A Difference Of No Greater Than 10%.

If The Specified Value Was Not Obtained Or No Speed Was Displayed

Check the wiring from the Motronic Engine Control Module (ECM) -J623- electrical harness connector to the Instrument Cluster Control Module -J285- for an open circuit, Short to Battery (+), or to Ground. Refer to appropriate Wiring Diagram information.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

VOLTAGE SUPPLY, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram

Test Requirements

1. Battery voltage at least 12.5 V
2. Fuel pump relay OK
3. Fuses OK
4. Generator OK
5. Ground connections between engine/transmission/chassis OK

Test Procedure

Remove the Motronic Engine Control Module (ECM) -J623-. Refer to the appropriate Service Information for removal and installation procedures.

Checking The Voltage Supply Circuits

Using a multimeter, measure the voltage of the Motronic Engine Control Module (ECM) -J623- voltage supply circuits. Refer to appropriate System Wiring Diagram information.

Switch the ignition on.

Specified Value: 12.5 V

If The Specified Value Was Not Obtained

Check the power supply circuits to the engine control module power supply relay for an open circuit, a short circuit or high resistance.

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

Repair as necessary.

If No Malfunctions Are Found In The Wiring

Checking The Ground Circuits

Using a multimeter, measure the resistance of the Engine Control Module (ECM) -J623- ground circuits. Refer to appropriate System Wiring Diagram information.

Specified Value: 1.5 ohms Max.

If The Specification Was Not Obtained

Check the circuit for an open circuit or high resistance.

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

Repair as necessary.

If No Malfunctions Are Found In The Wiring And The Voltage Supply Was OK

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

Generate readiness code. Refer to READINESS CODE .

Perform a road test to verify any electrical repairs.

Check the DTC memory. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY .

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

Replace the engine control module. Refer to the appropriate Service Information for removal and installation procedures.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .

ECM POWER SUPPLY RELAY, CHECKING

Observe all safety precautions: SAFETY PRECAUTIONS

View clean working conditions: CLEAN WORKING CONDITIONS

Prior to repair work, perform a preliminary check to verify the condition. Refer to PRELIMINARY CHECK .

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.

See Appropriate Wiring Diagram Information for component locations and connector views.

Special Tools And Workshop Equipment Required

1. Multimeter
2. Wiring diagram

Test Requirements

1. The engine control module fuses OK
2. Battery voltage at least 12.5 volts
3. All electrical consumers switched off
4. Vehicles with automatic transmission, shift selector lever in park or neutral
5. A/C switched off
6. Ground connections between engine/transmission/chassis OK
7. Check for any open fuses. If found, locate the short on that circuit and replace the fuse before continuing. Refer to Appropriate Wiring Diagrams for specific circuit information.
8. Ignition switched Off

Test Procedure

Remove the ECM Power Supply Relay -J317- from the fuse panel. Refer to Appropriate Wiring Diagrams for location.

Checking the supply voltage

Turn the ignition switch ON

Using a multimeter, measure the voltage of the ECM Power Supply Relay -J317- circuit, (socket 1/30).

Specified Value: Battery Voltage.

Turn the ignition switch OFF

If The Specified Value Was Not Obtained

Check the power supply circuit to the ECM Power Supply Relay -J317- for an open circuit or a short circuit. Refer to appropriate System Wiring Diagram information.

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

Repair as necessary.

If The Specified Value Was Obtained

Turn the ignition switch ON

Using a multimeter, measure the voltage of the ECM Power Supply Relay -J317- ignition circuit (socket 3/86).

Turn the ignition switch OFF

Specified Value: Battery Voltage.

If The Specified Value Was Not Obtained

Check the power supply circuit to the ECM Power Supply Relay -J317- for an open circuit or a short circuit. Refer to appropriate System Wiring Diagram information.

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

If The Specified Value Was Obtained

Checking wiring

Remove the Engine Control Module (ECM) -J623-. Refer to the Repair information for removal and installation procedures.

Using a multimeter, measure the resistance of the circuit between the ECM Power Supply Relay -J317- terminal 85 and the Engine Control Module (ECM) -J623- T94/69. Refer to the applicable wiring diagram.

Specified Value: 1.5 ohms Max.

If The Specification Was Not Obtained

Check the wires for a short circuit to each other, a short to battery voltage, and a short to ground.

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

Repair as necessary.

If No Malfunction Is Found In The Wiring And Voltage Supply Was Ok

Replace the ECM Power Supply Relay -J317-.

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-480996-S28584990252012061900000) .
2. If necessary, erase the DTC memory. Refer to «DIAGNOSTIC MODE 04 - ERASE DTC MEMORY»(ref-480996-S03858733152012061900000) .
3. If the DTC memory was erased, generate readiness code. Refer to «READINESS CODE»(ref-480996-S13819709122012061900000) .