remains127.0.0.1

28-1Ignitionsystem,checkingGeneralnotesonignitionsystemAlwaysswitchofftheignitionbeforeconnectingordisconnectingthebattery,otherwisetheenginecontrolmodulemaybedamaged.
TheenginecontrolmoduleisequippedwithOnBoardDiagnostic(OBD).
Fortrouble-freeoperationoftheelectricalcomponentsavoltageofatleast11.
5Visnecessary.
Duringsomeofthetestsitispossiblethatthecontrolmodulewilldetectandrecordamalfunction.
TheDTCmemorymustthereforebecheckedandifnecessaryerasedwhenalltestsandrepairworkhavebeencompleted.
Aftercompletingtroubleshooting,repairsorcomponenttests,itispossiblethattheenginewillstart,runforashortperiodandthencutout.
Ifthishappensitmaybethattheimmobilizerisblockingtheenginecontrolmodule.
InsuchcasestheDTCmemorymustbecheckedandifnecessarythecontrolmodulemustbeadapted.
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1428-2SafetyprecautionsTopreventinjuriestopersonsand/ordamagetothefuelinjectionandignitionsystem,thefollowingmustbenoted:WARNING!
Bealertwhenworkingonorneartheengine.
Highignitionsecondaryvoltagecancauseseriouspersonalinjuryanddamagevehiclecomponents.
DONOTtouchordisconnectignitionwiringwhentheengineisrunningorbeingturnedatstarterspeed.
DONOToperatethestarteriffuelinjectorsareremoved.
Alwaysswitchofftheignitionbeforeconnectingordisconnectingthebattery,otherwisetheenginecontrolmodulemaybedamaged.
Theignitionmustbeswitchedoffbeforeconnectingordisconnectinginjectionorignitionsystemwiringortestercables.
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14withoutactuallystartingit(e.
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totestcompression),disconnecttheconnectorsfromtheoutputstagesoftheignitioncoilsandfromallthefuelinjectors.
Aftercompletingthework,checkanderasetheDTCmemory.
Theignitionmustalwaysbeswitchedoffwhencleaningtheengine.
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1428-3CAUTION!
Beforedisconnectingthebattery:Stoptheengine.
Besureofproperradiocode(forvehiclesequippedwithcodedanti-theftradio).
Whenconnectinganddisconnectingelectricaltestequipment(LEDvoltagetester,multimeter,etc.
):BesuretheignitionisswitchedOFF.
UsecorrectadaptersfromVAG1594connectortestkitPage4of82Ignitionsystem,checking1/17/2006http://127.
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1428-4Technicaldata,ignitionsystemEnginecodeAPB(TLEVengine)BEL(LEVengine)EngineidleRPMNotadjustable-controlledbyIdleAirControl(IAC)650-750RPMRPMlimitOperatesbyclosingthrottlevalveOperatesbyshuttingofffuelinjectorsapprox.
6800RPMIgnitiontimingisdeterminedbythecontrolmodule.
Ignitiontimingcannotbeadjusted.
IgnitionsystemSingle-coilsystemwith6ignitioncoilslocatedabovesparkplugconnectorsandinstalleddirectlyonsparkplugs.
OnPBenginepoweroutputstagesarelocatedasseparatecomponentsinaircleanerhousing.
OnBELenginepoweroutputstagesareintegratedintoignitioncoils.
SparkplugsconnectorsResistanceapprox.
:2kOhmPage5of82Ignitionsystem,checking1/17/2006http://127.
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14Firingorder1-4-3-6-2-5Page6of82Ignitionsystem,checking1/17/2006http://127.
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1428-5Ignitioncoils,checkingNote:ThefollowingprocedureisforvehicleswithenginecodeAPB.
TheprocedureforvehicleswithenginecodeBELisonPage28-11.
MisfiringisrecognizedbytheOnBoardDiagnostic(OBD).
Thismeansanon-workingcylinderisstoredwiththecylindernumberintheDTCmemory.
Thishasanadvantageincaseofamalfunctionthetroubleshootingprocedurecanbestartedatacertaincylinder.
ChecktheDTCmemoryoftheEngineControlModule(ECM)beforecommencingtroubleshooting.
TestconditionsNoDTCsstoredrelatingtoanyofthefuelinjectorsDetermineanon-workingormisfiringcylinderasfollows:Page7of82Ignitionsystem,checking1/17/2006http://127.
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1428-6-Withenginerunningdisconnectharnessconnectorsinsequencefromfuelinjectors,andobserveengineperformance.
or-Comparesparkplugsofallcylinderswitheachotherandcheckforsootonelectrodes.
Whenthefaultycylinderhasbeenidentified:-Connecthand-heldmultimeter(resistancemeasurement)tosparkplugconnector:Note:Thesparkplugconnectorcanbedisconnectedfromtheignitioncoil.
Specification:approx.
:2kOhm.
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1428-7Ifspecificationisnotobtained:-Replacesparkplugconnector.
Ifspecificationisobtained:-Exchangesparkplugfromfaulty(misfiring)cylinderwithonefromanothercylinder.
Visuallychecksparkplugfordamage,e.
g.
cracksonceramicbodyofsparkplug.
-Ifmalfunction(misfire)occursnowonothercylinder,replacesparkplug.
Ifthemalfunctionremainsatthesamecylinder:-Exchangeignitioncoilfromfaulty(misfiring)cylinderwithonefromanothercylinder.
Visuallycheckignitioncoilfordamage(ignitioncoilcouldbecrackedorbursted)-Ifmalfunctionoccursnowonothercylinder,replaceignitioncoil.
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1428-8Ifmalfunctionremainsatthesamecylinder.
-Disconnectharnessconnectorfromignitioncoil.
ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsIftheGround(GND)connectionisOK.
-CheckGround(GND)connectionbetweensocket4aandengineGround(GND)foropencircuitandshortcircuittoB+.
-Repairanyopen/shortcircuitasnecessary.
-Connecthand-heldmultimeter(voltagerange)toterminal15ofharnessconnectorandGround(GND).
-Disconnectharnessconnectorfromfuelinjectorofcylindertobetested.
-Operatestarter.
Specification:approx.
batteryvoltagePage10of82Ignitionsystem,checking1/17/2006http://127.
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1428-9Ifthespecificationisnotobtained:-Checkwiring.
ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsIfthespecificationisobtained:-Disconnect3-pinharnessconnectorsonpoweroutputstagesforignitioncoils;componentlocationsoverviewPage24-5.
-ConnectLEDvoltagetesterto3-pinconnectorsforbothoutputstages.
Ifthespecificationsarenotobtained:-ConnectLEDvoltagetesterVAG1527tofollowingcontactsonconnectorsforpoweroutputstages:3-pinharnessconnectorterminalSpecification(withstarteractivated)1+Ground(GND)LEDvoltagetestermust2+Ground(GND)lightup3+Ground(GND)Page11of82Ignitionsystem,checking1/17/2006http://127.
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14-Switchignitionoff.
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1428-10-Checkfollowingwiringconnectionsforopencircuitsand/orshorttoB+orGround(GND).
Black3-pinconnectoronpoweroutputstage,terminal3-pinconnectoronignitioncoil,terminal11(cylinder1)21(cylinder2)31(cylinder3)-Checkfollowingwiringconnectionsforopencircuitsand/orshorttoB+orGround(GND).
Brown3-pinconnectoronpoweroutputstage,terminal3-pinconnectoronignitioncoil,terminal11(cylinder4)21(cylinder5)31(cylinder6)-Eliminateanyopen/shortcircuitasnecessary.
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1428-11Ignitioncoils,checking,EnginecodeBELNote:Theignitioncoilandthepoweroutputstageareintegratedinonecomponent.
RequirementsNoDTCsstoredrelatingtoanyofthefuelinjectorsDetermineanon-functionalormisfiringcylinderasfollows:-Checkmisfirerecognition,Page28-66Ifamisfireisrecognized:-Continuewithcylinderdisplayedusingtest"Ifamisfireisrecognized".
Ifnomisfireisrecognized:-Withenginerunning,disconnectconnectorsfrominjectorsoneatatimeandobservehowengineisrunning.
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1428-12or-Comparesparkplugsofallcylinderswitheachotherandlookforcorrodedelectrodes.
Ifthefaultycylinderisfound:-Exchangesparkplugfromfaultycylinderwithonefromanothercylinder.
Ifproblemcylindermoveswiththesparkplug:-Replacesparkplug.
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1428-13Ifthefaultremainswiththecylinder:-Exchangeignitioncoilfromfaultycylinderwithonefromanothercylinder.
-Iffaultnowappearsinanothercylinder,replaceignitioncoil.
Ifthefaultremainswiththecylinder:-CheckGroundwiringofignitioncoil.
CheckingGroundwiringofignitioncoil-Disconnect4-pinconnectoronrespectiveignitioncoil.
IfGroundwiringisOK:-CheckGroundwiringonsocket4of4-pinconnectorafterengineGroundforopencircuitorshortcircuittoB+.
-Eliminateanyopenorshortcircuits.
-CheckvoltagesupplytoignitioncoilPage28-14.
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1428-14CheckingvoltagesupplyoftheignitioncoilsSpecifiedvalue:approx.
batteryvoltageIfthespecifiedvalueisnotattained:ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsIfthespecificationisnotobtained:-Connectmultimeterformeasuringvoltagetofollowingsocketsonconnector:-Switchignitionon.
4-pinharnessconnectorterminalSpecification1+Ground(GND)Batteryvoltage-Checkwiringconnectionforsocket1viafusetoMotronic(ECM)powersupplyrelay-J271-forcontinuityandrepairifnecessary.
-CheckECMpowersupplyrelay-J271-Page28-24.
-CheckpoweroutputstagePage28-15.
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1428-15Poweroutputstagesforignitioncoils,checkingNote:ThefollowingprocedureisforvehicleswithenginecodeAPB.
TheprocedureforvehicleswithenginecodeBELisonPage28-20.
PowerOutputStage-N122-(blackconnector)activatestheignitioncoilsforcylinderbank1(cylinders1to3).
PowerOutputStage2-N192-(brownconnector)activatestheignitioncoilsforcylinderbank2(cylinders4to6).
Checkingactivationofpoweroutputstages-Disconnectharnessconnectorsfromallsixfuelinjectors.
Note:Itisimportanttoensurethatnofuelisinjectedduringthetestasthiswoulddamagethecatalyticconverter.
Theharnessconnectorsonthefuelinjectorsmustthereforebedisconnected.
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1428-16-Disconnect4-pinharnessconnectorsonpoweroutputstagesComponentlocationsoverview,Page24-5.
-ConnectLEDvoltagetesterVAG1527inturntofollowingcontactsontwo4-pinconnectorsforpoweroutputstages.
-Operatestarterforafewseconds.
6-pinconnectoronwiringharness,terminalSpecification1+Ground(GND)LEDvoltagetestermust3+Ground(GND)flash(briefimpulse)4+Ground(GND)Page19of82Ignitionsystem,checking1/17/2006http://127.
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1428-17Ifthespecificationsarenotobtained:-Switchignitionoff.
-ConnecttestboxVAG1598/31towiringharnessforenginecontrolmodule.
Donotconnecttoenginecontrolmoduleitself.
Page24-20.
-Checkfollowingwiringconnectionsforopencircuitsand/orshorttoB+orGround(GND):Black4-pinconnectoronwiringharness,terminalVAG1598/31testbox,socket19431104102Brown4-pinconnectoronwiringharness,terminalVAG1598/31testbox,socket19531114103Page20of82Ignitionsystem,checking1/17/2006http://127.
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1428-18-Correctanyopen/shortcircuitasnecessary.
Ifnowiringmalfunctionisdetected:-Connect4-pinconnectorstopoweroutputstages.
-Disconnect3-pinconnectorsfrompoweroutputstages.
-ConnectLEDvoltagetesterVAG1527tobattery(B+)andtooneof3terminalsonpoweroutputstage.
-Operatestarterforfewseconds.
LEDvoltagetestershouldflash.
-Performtestwithall3terminalsoneachof3-pinconnectorsforpoweroutputstages.
LEDvoltagetestershouldflasheachtime.
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1428-19IftheLEDvoltagetesterdoesnotflashwhentestingoneormoreofthecontacts:-ChecktheGround(GND)connectionsforthepoweroutputstagesasfollows:-Disconnect4-pinconnectorfrompoweroutputstages.
-ConnectLEDvoltagetesterVAG1527tobattery(B+)andterminal2ofeach4-pinconnectorinturn.
LEDvoltagetestershouldlightup.
IfLEDvoltagetesterdoesnotlightup,-Testforopencircuitinwiringusingwiringdiagram.
ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsIftheLEDvoltagetesterlightsup:-Replacepoweroutputstage.
Note:Page22of82Ignitionsystem,checking1/17/2006http://127.
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14Beforeinstallingnewpoweroutputstagecoatmetalsidewithheatpaste(partno.
G052170A1).
Theheatpasteisusedtopreventcorrosionbetweenthepoweroutputstageandthefasteningpointandtotransferheatfromthepoweroutputstage.
CAUTION!
Partnumbersareonlyforreference.
Alwayscheckwithyourpartsdepartmentforthelatestinformation.
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1428-20Poweroutputstagesforignitioncoils,checking,EnginecodeBELNote:TheignitioncoilsandthepoweroutputstagesarecontainedinonecomponentCheckingGroundsupplyforpoweroutputstages-Disconnect4-pinconnectorforeachignitioncoil.
ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsIfGroundwiringisOK:-Checkwiringconnectionfromsocket2of4-pinconnectorafterbodyGroundforopencircuitorshortcircuittoGround.
-Repairopenorshortcircuitasnecessary.
-CheckactivationofpoweroutputstagesPage28-21.
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1428-21Checkingactivationofpoweroutputstages-Disconnectharnessconnectorsfromallsixfuelinjectors.
Note:Itisimportanttoensurethatnofuelisinjectedduringthetestasthiswoulddamagethecatalyticconverter.
Theharnessconnectorsonthefuelinjectorsmustthereforebedisconnected.
-Disconnect4-pinforeachignitioncoil.
Ifthespecifiedvalueisnotattained:-ConnectLEDvoltagetesterV.
A.
G1527tofollowingcontactsonconnectorsforigntioncoils.
-Operatestarterforafewseconds.
4-pinconnectoronwiringharness,terminalSpecification3+2LEDvoltagetestermustflash(briefflash)-Switchignitionoff.
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1428-22-ConnecttestboxV.
A.
G1598/31towiringharnessforenginecontrolmodule.
Donotconnecttoenginecontrolmoduleitself,Page24-20.
-Checkwiringconnectionfrom4-pinconnectoronignitioncoilandpoweroutputstages.
.
.
.
-.
.
.
.
.
toenginecontrolmoduleforopencircuitsandshortscircuitstoB+andGround4-pinconnectorVAG1598/31testbox,socketCyl.
1102Cyl.
2110Cyl.
394Cyl.
4103Cyl.
5111Cyl.
695Wireresistance:max.
1.
5OhmPage26of82Ignitionsystem,checking1/17/2006http://127.
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1428-23-Repairanyopenciruitsandshortcircuits.
ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsIfthereisnofaultinthewiring:-Replaceignitioncoilwithpoweroutputstage.
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1428-24MotronicECMpowersupplyrelay-J271-,checkingLocationofrelay:ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsNote:TheMotronicECMpowersupplyrelay-J271-suppliestheignitioncoilswithpoweroutputstagesandalsosuppliestheECMonpin3andsomeothercomponentswithvoltage.
Whentheignitionison,theremustbe1-12Voltsoncontactattherespectiveignitioncoil.
CheckactivationwiringfrompowersupplyrelaytoECM-Switchignitionon.
-RemoveMotronicECMpowersupplyrelay-J271-from3-positionrelaypanel.
-ConnectV.
A.
G1598/31testboxtowiringharnessforenginecontrolmodule.
Donotconnecttoenginecontrolmoduleitself,Page24-20.
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1428-25-Checkfollowingwiringconnectionsforopencircuitorshortcircuit:VAG1598/31testbox,socketPowersupplyrelayterminal234ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsWireresistance:max.
1.
5Ohm-Correctanyopen/shortcircuitsasnecessary.
ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsIfnowiringfaultisfound:-Checkvoltagesupplyforpowersupplyrelay,Page28-26.
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1428-26Checkingvoltagesupplytopowersupplyrelay-Switchignitionoff.
-Connectmultimeterforvoltagemeasurementbetweenterminal1onrelaysocketandGround.
-Connectmultimeterforvoltagemeasurementbetweenterminal2onrelaysocketandGround.
Specifiedvalue:approx.
batteryvoltageIfthespecifiedvalueisnotattained:-Checkvoltagesupplyaccordingtowiringdiagram.
ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsIfthespecifiedvalueisattained:-Checkwiringconnectionbetweenpowersupplyrelayandenginecontrolmodule,Page28-27.
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1428-27Checkingwiringconnectionbetweenpowersupplyrelayandenginecontrolmodule-Checkfuse.
ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsIfnofaultisfoundwithfuse:-Checkfollowingwiringconnectionsforopencircuitorshortcircuit:VAG1598/31testbox,socketPowersupplyrelayterminal38ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsWireresistance:max.
1.
5Ohm-Correctopencircuitorshortcircuitasnecessary.
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14Ifnofaultisfoundinanyofthetests:-ReplaceMotronicECMpowersupplyrelay-J271-.
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1428-28IntakeAirTemperature(IAT)sensor-G42-,checkingLocationofsensorandconnectorPage24-5.
-Connectvehiclediagnostic,testingandinformationsystemVAS5051orVAG1551scantoolandselectengineelectronicscontrolmodulebyenteringaddressword"01"Page01-8.
Ignitionmustbeswitchedon.
RapiddatatransferHELPSelectFunctionXXIndicatedondisplay-Pressbuttons-0-and-8-toselectfunction"ReadMeasuringValueBlock"andconfirmentrywith-Q-button.
ReadMeasuringValueBlockHELPInputDisplayGroupNumberXXXIndicatedondisplay-Pressbuttons-0-,-0-and-4-toselect"displaygroup004"andconfirmentrywith-Q-button.
ReadMeasuringValueBlock41234Indicatedondisplay(1.
.
.
4displayfields)-Checkdisplayvalueforintakeairtemperaturesensor(displayfield4):Page33of82Ignitionsystem,checking1/17/2006http://127.
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1428-29Displayfields1234DisplayGroup004:IntakeairtemperaturewithengineidlingDisplayxxxxRPMxx.
xxxVxxx.
xCxxx.
xCIndicatesEnginespeedBatteryvoltageCoolanttemperatureIntakeairtemperatureWorkrangemin.
:650RPMmax.
:6800RPMmin.
:10.
000Vmax.
:15.
000Vmin.
:-48.
0Cmax.
:143.
0Cmin.
:-48.
0Cmax.
:143.
0CSpecifiedvaluexxxxRPM12.
000.
.
.
15.
000V80.
0.
.
.
110.
0CBetweenambienttemp.
and120C1)1)Ifthereisalargedifferencebetweenthetemperaturedisplayedandtheambienttemperatureatthesensor,checkthesensorandsensorwiringforcontactresistanceandopencircuit.
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1428-30Checkingwiring:-Switchignitionoff.
-ConnecttestboxVAG1598/31towiringharnessforenginecontrolmodule.
Donotconnecttoenginecontrolmoduleitself.
Page24-20.
-Checkforopencircuitinwiringbetweentestboxand2pinharnessconnectorusingwiringdiagram.
Specification:max.
1.
5Terminalon2-pinharnessconnectorContactoncontrolmoduleconnectorortestbox1285108-Checkwiringforshortcircuitstoeachotherbetweencontacts1and2on2-pinconnector.
AlsotestforshortcircuitstoB+orGround(GND).
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1428-31Ifnomalfunctioninwireisdetected:CheckingsensorIfvaluedoesnotmatchthespecification:Note:Inordertoinstallthenewsensor,theintakemanifoldmustfirstberemovedPage24-15.
-Measureresistancebetweencontacts1(signal)and2(Ground)onconnectorforIntakeAirTemperature(IAT)sensor-G42-.
TemperatureCResistancek-20approx.
13.
80approx.
5.
520approx.
2.
440approx.
1.
160approx.
0.
6-Replaceintakeairtemperaturesensor.
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1428-32Enginespeed(RPM)sensor-G28-,checkingNote:Theenginespeedsenderisacombinedspeedsensorandreferencemarksensor.
WithoutasignalfromtheEngineSpeed(RPM)sensor-G28-theenginecannotbestarted.
IfthesignalfromtheEngineSpeed(RPM)sensor-G28-failswhiletheengineisrunning,theenginewillcutoutimmediately.
CheckingEngineSpeed(RPM)sensorComponentlocationofsensorandconnectorPage24-5.
-Beforeperformingtest,makesurethatsensoriscorrectlyinstalledandfirmlyseated.
-DisconnectharnessconnectorforEngineSpeed(RPM)sensor(grayconnector).
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1428-33Note:Ifthespecificationisnotattained:Ifthespecificationisattained:Ifthespecificationisnotattained:Ifthespecificationisattained:-Connectmultimeter(Fluke83orequivalent)(resistancetestrange)toterminals2and3onconnectorforenginespeedsensorusingtestleadfromVAG1594connectortestkit.
Specification:approx.
730-1000OhmTheresistancevaluefortheenginespeedsensorisbasedonatemperatureof20C.
Theresistanceincreasesasthetemperaturerises.
-ReplaceEngineSpeed(RPM)sensor.
-Connectmultimeter(Fluke83orequivalent)(resistancetestrange)betweenterminals2and1(Ground)andbetweenterminals3and1(Ground).
Specification:R(infiniteOhms/opencircuit)ineachtest-ReplaceEngineSpeed(RPM)sensor.
-CheckwiringbetweensensorconnectorandenginecontrolmoduleasPage38of82Ignitionsystem,checking1/17/2006http://127.
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14follows:Page39of82Ignitionsystem,checking1/17/2006http://127.
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1428-34-ConnectVAG1598/31testboxtowiringharnessforenginecontrolmodule.
DonotconnecttoenginecontrolmoduleitselfPage24-20.
-Testcontinuityofscreening(shieldedwire)betweencontact1onenginespeedsensorconnectorandsocket108ontestbox.
Specification:max.
1.
-Testcontinuityofnegativewirefromcontact2onsensorconnectortosocket90ontestbox.
Specification:max.
1.
-Testcontinuityofsignalwirefromcontact3onsensorconnectortosocket82ontestbox.
Specification:max.
1.
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1428-35Ifthevaluesarenotasspecified:-Correctshortoropencircuitinwiringbetweensensorconnectorandcontrolmoduleconnector.
TerminalonsensorconnectorTerminaloncontrolmoduleconnector1231089082-Ifnoopencircuitsorshortcircuitsareidentified,replaceEngineControlModule(ECM)Page24-24.
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1428-36EngineCoolantTemperature(ECT)sensor-G62-,checkingNote:ComponentlocationofcoolanttemperaturesensorPage24-5.
TestconditionsEnginecold-Connectvehiclediagnostic,testingandinformationsystemVAS5051orVAG1551scantooltovehicleandselectengineelectronicscontrolmodulebyenteringaddressword"01"Page01-8.
Enginemustbeatidle.
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1428-37RapiddatatransferHELPSelectfunctionXXIndicatedondisplay-Pressbuttons-0-and-8-toselectfunction"ReadMeasuringValueBlock"andconfirmentrywith-Q-button.
ReadMeasuringValueBlockInputdisplaygroupnumberXXXIndicatedondisplay-Pressbuttons-0-,-0-and-4-toselect"displaygroup004"andconfirmentrywith-Q-button.
ReadMeasuringValueBlock41234Indicatedondisplay-Checkspecificationindisplayfield3.
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1428-38Displayfields1234DisplayGroup004:CoolanttemperaturewithengineidleDisplayxxxxRPMxx.
xxxVxxx.
xCxxx.
xCIndicatesEnginespeedRPMBatteryvoltageCoolanttemperatureIntakeairtemperatureSpecifiedvalueXXXXRPM12.
0.
.
.
15.
0VTemperaturemustincreaseevenlyAmbienttemperatureupto120CPage44of82Ignitionsystem,checking1/17/2006http://127.
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1428-39Ifdisplayfield3doesnotdisplayarealisticvalue:-Disconnectharnessconnectorfromcoolanttemperaturesensor.
Coolanttemperaturesensorwithsquareconnector-Connectmulti-meter(resistancemeasurement)betweenterminals1and3ofsensor.
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1428-40CoolanttemperaturesensorwithovalconnectorAllScaleAshowsresistancevaluesfortemperaturerange0-50CandscaleBthevaluesfortemperaturerange50-100C.
-Connectmulti-meter(resistancemeasurement)betweenterminals3and4ofsensor.
Examples:Ifvaluedoesnotmatchthespecification:30Ccorrespondstoaresistancefrom1500.
.
.
200080Ccorrespondstoaresistancefrom275.
.
.
375-Replacecoolanttemperaturesensor.
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1428-41Ifthevaluedoesmatchthespecification:-ConnecttestboxVAG1598/31towiringharnessforenginecontrolmodule.
Donotconnecttoenginecontrolmoduleitself.
Page24-20.
CoolanttemperaturesensorwithsquareconnectorCoolanttemperaturesensorwithovalconnector-CheckfollowingwiringconnectionsforopencircuitsandshortcircuitstoB+orGround(GND)HarnessconnectorTerminalVAG1598/31testboxSocket1(Signal)933108-CheckfollowingwiringconnectionsforopencircuitsandshortcircuitstoB+orGround(GND)HarnessconnectorTerminalVAG1598/31testboxSocket31084(Signal)93Page47of82Ignitionsystem,checking1/17/2006http://127.
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1428-42All-Checkwiresforshortcircuitstoeachother.
-Ifnecessaryeliminateopencircuitorshortcircuit.
Ifnomalfunctionisidentifiedinthewiring:-ReplaceEngineControlModule(ECM)Page24-24.
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1428-43Controlmodulevoltagesupply,checkingProcedureisvalidforengineswithEnginecode.
ProcedureforEnginecodeBELPage28-45TestrequirementsFuseforEngineControlModule(ECM)OKElectricalWiringDiagrams,Troubleshooting&ComponentLocations.
Batteryvoltageatleast11VGeneratorOK-ConnecttestboxVAG1598/31towiringharnessforenginecontrolmodule.
Donotconnecttoenginecontrolmoduleitself.
Page24-20.
-Switchignitionon.
Note:TheB+voltagesupplyfortheenginecontrolmodulecomesviaterminal3(terminal15)andterminal62(terminal30).
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14TheGround(GND)connectionfortheenginecontrolmoduleisviaterminals1and2.
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1428-44-ConnectmultimeterVAG1526(voltagemeasurementrange)tofollowingcontactsontestbox:ContactSpecification3+2approx.
batteryvoltage3+1approx.
batteryvoltage62+2approx.
batteryvoltageIfthespecificationsarenotobtained:-Checkwiring.
ElectricalWiringDiagrams,Troubleshooting&ComponentLocations.
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1428-45Controlmodulevoltagesupply,checking,EnginecodeBELTestrequirementsEnginecontrolmodulefuseOKElectricalWiringDiagrams,Troubleshooting&ComponentLocationsBatteryvoltage11VminimumGeneratorOK-ConnectV.
A.
G1598/31testboxtowiringharnessforenginecontrolmodule.
Donotconnecttoenginecontrolmoduleitself,Page24-20.
-Switchignitionon.
Note:TheB+voltagesupplyfortheenginecontrolmoduletravelsviaconnectorterminal3(fromMotronicECMpowersupplyrelay-J271-),connectorterminal21(terminal15)andconnectorterminal62(terminal30).
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14Ground(GND)supplyoftheenginecontrolmoduleisviaconnectorterminals1and2.
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1428-46-Connectmultimeterforvoltagemeasurementtofollowingcontactsontestbox:ContactSpecification3+2approx.
batteryvoltage3+1approx.
batteryvoltage21+1approx.
batteryvoltage62+2approx.
batteryvoltageIfthespecificationsarenotobtained:-Checkwiringconnections.
ElectricalWiringDiagrams,Troubleshooting&ComponentLocationsIfthespecificationsonterminal3arenotobtained:-CheckMotronicECMpowersupplyrelay,Page28-24.
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1428-47Knocksensorcontrollimit,checkingIfthemalfunctionmessage"Knockcontrolregulationreached"isrecordedintheDTCmemorythefollowingtestsmustbecarriedout.
Seealsomeasuringvalueblocks20,21,22,23and24Page28-48PossiblecauseofmalfunctionCorrectiveactionMalfunctionmessagerelatingtoallcylindersPoorfuelquality-Changetohigherqualityfuel(seeOwner'sManual)ormalfunctionmessagerelatingtoallcylindersinonebankIncorrecttighteningtorqueonknocksensor-Loosenknocksensor,thentightento20Nm(15ftlb)Knocksensorfaulty-CheckknocksensorPage28-54.
CorrosiononconnectorLoosecomponentsonengine-SecureloosecomponentsMalfunctionmessagerelatingtoonecylinderMechanicalenginedamage-CheckcompressionpressureLoosecomponentsonengine-SecureloosecomponentsPage55of82Ignitionsystem,checking1/17/2006http://127.
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1428-48MeasuringvalueblocksforignitiontimingangleretardDisplayGroup020-Ignition-KnockcontrolDrivingmodeReadmeasuringvalueblock20Indicatedondisplayxx.
xKWxx.
xKWxx.
xKWxx.
xKW1234DisplayfieldsSpecifiedvalueEvaluationIgnitiontimingretardviaknockcontrol:cylinder40.
.
.
12KW(crankshaftangle)Page28-53Ignitiontimingretardviaknockcontrol:cylinder30.
.
.
12KW(crankshaftangle)Page28-53Ignitiontimingretardviaknockcontrol:cylinder20.
.
.
12KW(crankshaftangle)Page28-53Ignitiontimingretardviaknockcontrol:cylinder10.
.
.
12KW(crankshaftangle)Page28-53Note:Page56of82Ignitionsystem,checking1/17/2006http://127.
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14Thedisplayeddigitvaluesindisplayfields1to4reflectstheactual"ignitiontimingretard"viaknockcontrolfromtheindividualcylinders.
TheignitiontimingretardoccursviaKW(crankshaftangle).
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1428-49DisplayGroup021-Ignition-KnockcontrolDrivingmodeReadmeasuringvalueblock21Indicatedondisplayxx.
xKWxx.
xKW1234DisplayfieldsSpecifiedvalueEvaluationIgnitiontimingretardviaknockcontrol:cylinder60.
.
.
12KW(crankshaftangle)Page28-53Ignitiontimingretardviaknockcontrol:cylinder50.
.
.
12KW(crankshaftangle)Page28-53Note:Thedisplayeddigitvaluesindisplayfields1and2reflectstheactual"ignitiontimingretard"viaknockcontrolfromtheindividualcylinders.
TheignitiontimingretardoccursviaKW(crankshaftangle).
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1428-50DisplayGroup022-Ignition-KnockcontrolDrivingmodeReadmeasuringvalueblock22Indicatedondisplayxx.
xRPMx.
x%xx.
xKWxx.
xKW1234DisplayfieldsSpecifiedvalueEvaluationIgnitiontimingretardviaknockcontrol:cylinder20.
.
.
12KW(crankshaftangle)Page28-53Ignitiontimingretardviaknockcontrol:cylinder10.
.
.
12KW(crankshaftangle)Page28-53Engineload15-175%EnginespeedRPM650-6800RPMNote:Thedisplayeddigitvaluesindisplayfields3and4reflectstheactual"ignitiontimingretard"viaknockcontrolfromcylinders1and2.
TheignitiontimingretardoccursviaKW(crankshaftangle).
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1428-51DisplayGroup023-Ignition-KnockcontrolDrivingmodeReadmeasuringvalueblock23Indicatedondisplayxx.
xRPMx.
x%xx.
xKWxx.
xKW1234DisplayfieldsSpecifiedvalueEvaluationIgnitiontimingretardviaknockcontrol:cylinder40.
.
.
12KW(crankshaftangle)Page28-53Ignitiontimingretardviaknockcontrol:cylinder30.
.
.
12KW(crankshaftangle)Page28-53Engineload15-175%EnginespeedRPM650-6800RPMNote:Thedisplayeddigitvaluesindisplayfields3and4reflectstheactual"ignitiontimingretard"viaknockcontrolfromcylinders3and4.
TheignitiontimingretardoccursviaKW(crankshaftangle).
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1428-52DisplayGroup024-Ignition-KnockcontrolDrivingmodeReadmeasuringvalueblock24Indicatedondisplayxx.
xRPMx.
x%xx.
xKWxx.
xKW1234DisplayfieldsSpecifiedvalueEvaluationIgnitiontimingretardviaknockcontrol:cylinder60.
.
.
12KW(crankshaftangle)Page28-53Ignitiontimingretardviaknockcontrol:cylinder50.
.
.
12KW(crankshaftangle)Page28-53Engineload15-175%EnginespeedRPM650-6800RPMNote:Thedisplayeddigitvaluesindisplayfields3and4reflectstheactual"ignitiontimingretard"viaknockcontrolfromcylinders5and6.
TheignitiontimingretardoccursviaKW(crankshaftangle).
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1428-53Evaluationdisplaygroups20/21/22/23/24,-IgnitiontimingangleretardIndicatedondisplayMalfunctioncauseCorrectiveactionAllcylindersgreaterthan12KWKnocksensorfaulty-CheckknocksensorPage28-54.
CorrodedconnectionKnocksensorincorrecttighteningtorque-Loosenandtightenknocksensorwith20Nm(15ftlb)Componentsonengineloose-TightencomponentsLowfuelgrade-ChangefuelgradeOnecylinderdeviatesclearlyfromothersCorrodedconnection-CheckknocksensorPage28-54.
EnginedamageRepairManual,2.
7LiterV65VBiTurbo,EngineMechanical,EngineCode(s):APB,BEL,RepairGroup15;Cylinderheadremoving,checkcompressionpressure-Checkcompressionpressure:Componentsonengineloose-TightencomponentsPage62of82Ignitionsystem,checking1/17/2006http://127.
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1428-54KnockSensor(KS)1-G61-andKnockSensor(KS)2-G66-,checkingNotes:Itisnotpossibletoperformanelectricaltestoftheknocksensorsthemselves.
Useonlygold-platedterminalswhenrepairingtheterminalsintheplugconnectorsfortheknocksensors.
Toensurethattheknocksensorsfunctionproperlyitisimportanttokeepexactlytothespecifiedtighteningtorqueof20Nm(15ftlb)Checkforcorrosioninconnectionbetweenknocksensorandwiringharness.
CheckingknocksensorsNote:-Disconnectharnessconnectorforrelevantknocksensorinenginecompartment.
ComponentlocationoverviewPage24-5.
Inordertoreachtheconnectorfortheknocksensorforcylinderbank2,firstremovetheboltssecuringthecoolantreservoirandmovethePage63of82Ignitionsystem,checking1/17/2006http://127.
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14coolantreservoirtooneside.
Coolanthosesremainattached.
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1428-55AssignmentofconnectorsforengineswithenginecodeBELPage28-56.
Ifthereisaconnectionbetweentheterminals.
Note:IfthereisnoshortcircuitCheckingwiringbetweenknocksensorsandenginecontrolmodule-Checkforshortcircuitsbetweenallthreeterminalsinknocksensorconnector(terminals1+2,1+3and2+3).
Specification:Theremustbenocontactbetweenthewires(infinite).
-Replaceknocksensor.
Inordertoreachtheknocksensors,firstremovetheairductPage24-52.
Usespecialtool3247toremovetheknocksensors.
-Checkwiringforknocksensors.
-ConnectVAG1598/31testboxtowiringharnessforenginecontrolmodule.
DonotconnecttoenginecontrolmoduleitselfPage24-20.
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1428-56ConnectorsforEnginecodeBELAssignmentofconnectorwiringinvehicleswithenginecodeBELAssignmentof4-pinconnectorsonknocksensorsinvehicleswithenginecodeBELPage66of82Ignitionsystem,checking1/17/2006http://127.
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1428-57AssignmentofconnectorsforengineswithenginecodeBELPage28-56-Checkwiringconnectionfromrelevantsensorconnectorto.
.
.
-.
.
.
.
EngineControlModule(ECM)foropencircuitand/orshorttoB+orGround(GND).
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1428-58KnockSensor(KS)1-G61-(Bank1)3-pinconnectoronwiringharness,socketVAG1598/31testbox,socket1(Ground)992(signal)1063(shielded)108Knocksensor(KS)2-G66-(Bank2)3-pinconnectoronwiringharness,socketVAG1598/31testbox,socket1(Ground)992(signal)1073(shielded)108Resistanceinwiring:max.
1.
5ohm-Repairanyopen/shortcircuitasnecessary.
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1428-59CamshaftPosition(CMP)sensor2-G163-andCamshaftPosition(CMP)sensor1-G40-,checkingNotes:ComponentlocationsofCMPsensorsPage24-5.
TheCamshaftPosition(CMP)sensor2-G163-islocatedattherearoftheleft-handcylinderhead(Bank2).
TheCamshaftPosition(CMP)sensor1-G40-islocatedatthefrontoftheright-handcylinderhead(Bank1).
CheckingactivationofCMPsensorUsetestleadsVAG1594connectortestkitwhenperformingthefollowingtests.
-PushbackrubbergrommetonrelevantCMPsensorconnector.
Note:-ConnectVAG1527LEDvoltagetestertoterminals1and2ofCMPsensorconnectorfrombehind(withoutdisconnectingconnectorfromsensor).
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14Theconnectorterminalsarenumberedonthebackoftheconnector.
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1428-60-Operatestarterforfewseconds.
LEDvoltagetestershouldblinkbrieflyonceeverytwoenginerevolutions.
Note:LEDvoltagetesterswithalowcurrentdrawcontinuetoglowfaintlybetweenimpulsesfromtheenginecontrolmodule(ratherthangoingoutcompletely)andbecomemuchbrighterwhenreceivinganimpulse.
IftheLEDvoltagetesterdoesnotblink:-Checkvoltagesupply.
CheckingvoltagesupplyforCMPsensor-DisconnectharnessconnectorfromrelevantCMPsensor.
-Switchignitionon.
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1428-61CheckingsignalwireforCMPsensorCheckingGround(GND)wireforCMPsensor-Connectmultimeter(Fluke83orequivalent)(voltagemeasurementrange)betweenengineGround(GND)andsocket1ofconnector.
Specification:approx.
5V-Connectmultimeter(Fluke83orequivalent)(voltagemeasurementrange)betweenengineGround(GND)andsocket2ofrelevantconnector.
Specification:approx.
batteryvoltage-ConnectVAG1598/31testboxtowiringharnessforenginecontrolmodule.
DonotconnecttoenginecontrolmoduleitselfPage24-20.
-Connectmultimeter(Fluke83orequivalent)(resistancemeasurementrange)betweensocket3onrelevantconnectorandcontact108oftestbox.
Specification:ContinuityResistanceinwiring:max.
1.
5OhmsPage72of82Ignitionsystem,checking1/17/2006http://127.
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1428-62IfallspecificationsarereachedbuttheLEDvoltagetesterdoesnotblink(measurementtakenbetweenterminals1and2withoutunpluggingconnectorandwhileoperatingstarter):-ReplacerelevantCMPsensor.
Ifspecificationsareobtained:-Checkwiring.
CheckingwiringbetweenCMPsensorandEngineControlModule(ECM)-ConnectVAG1598/31testboxtowiringharnessforenginecontrolmodule.
DonotconnecttoenginecontrolmoduleitselfPage24-20.
-CheckwiringconnectionfromCMPsensortoenginecontrolmoduleforopencircuitand/orshortcircuittoB+orGround(GND).
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1428-63CamshaftPosition(CMP)sensor2-G163-(Bank2)3-pinconnectoronwiringharness,socketVAG1598/31testbox,socket1(B+)982(signal)863(Ground(GND))108CamshaftPosition(CMP)sensor1-G40-(Bank1)3-pinconnectoronwiringharness,socketVAG1598/31testbox,socket1(positive)982(signal)873(Ground(GND))108Resistanceinwiring:max.
1.
5ohm-Repairanyopen/shortcircuitasnecessary.
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1428-64IfallthetestresultssofarhavebeenOKbutamalfunctionrelatedtothecamshaftpositionsensor(Hallsensor)isdisplayedagainaftererasingtheDTCmemoryasatestmeasure,thefollowingmightbethecause:-Rotorring(triggerwheel)forcamshaftpositionsensor(Hallsensor)misaligned;testphaseposition.
CheckingphasepositionofCMPsensor-Connectvehiclediagnostic,testingandinformationsystemVAS5051orVAG1551scantoolandselectengineelectronicscontrolmodulebyenteringaddressword"01"Page01-8.
Enginemustbeidling.
RapiddatatransferHELPSelectfunctionXXIndicatedondisplay-Pressbuttons-0-and-8-toselectfunction"ReadMeasuringValueBlock"andconfirmentrywith-Q-button.
ReadMeasuringValueBlockInputdisplaygroupnumberXXXIndicatedondisplay-Pressbuttons-0-,-9-and-3-toselect"displaygroup093"andconfirmentrywith-Q-button.
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1428-65ReadMeasuringValueBlock931234Indicatedondisplay-CheckspecifieddisplayvaluesforCMPsensors.
Displayfields1234DisplayGroup093:PhasepositionsofHallsensors(Bank1andBank2)withengineidlingDisplayxxxRPMxx%06KW06KWIndicatesEnginespeed(RPM)EngineloadPhasepositionBank1PhasepositionBank2Workrangemin.
:750RPMmax.
:6800RPMmin.
:15%max.
:175%-20.
3to14.
8KW-20.
3to14.
8KWSpecifiedvalue650-850RPM15.
.
.
25%06KW06KWNoteIfreadoutsdonotmatchspecifications,unboltCMPsensorandcheckwhetherrotorringisproperlymountedoncamshaft.
Ifitisincorrectlymounted,thelocatinglugwillbeflattenedwhenthesecuringboltistightened.
Alsocheckvalvetiming.
RepairManual,2.
7LiterV65VBiTurboEngineMechanical,EngineCode(s):APB,BEL,RepairGroup13;Crankcaseventilation,Ribbedbeltremovingandinstalling,TimingbeltremovingandinstallingPage76of82Ignitionsystem,checking1/17/2006http://127.
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1428-66Misfirerecognition,checkingTestsequence-Connectvehiclediagnostic,testingandinformationsystemVAS5051orVAG1551scantoolandselectengineelectronicscontrolmodulebyenteringaddressword"01"Page01-8.
Enginemustbeatidle.
RapiddatatransferHELPSelectfunctionXXIndicatedondisplay-Pressbuttons-0-and-8-toselectfunction"ReadMeasuringValueBlock"andconfirmentrywith-Q-button.
ReadMeasuringValueBlockInputdisplaygroupnumberXXXIndicatedondisplay-Pressbuttons-0-,-1-and-4-toselect"displaygroup014"andconfirmentrywith-Q-button.
ReadMeasuringValueBlock141234Indicatedondisplay-Checkmisfirerecognition.
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1428-67Displayfields1234DisplayGroup014:MisfirerecognitionDisplayxxx/RPMxx.
x%xxx---IndicatedEnginespeed(RPM)LoadTotalmisfiresMisfirerecognitionWorkrangemin.
:650RPMmax.
:6800RPMmin.
:0max.
:175activatedlockedSpecifiedvalue650-720RPM15.
0-25.
0%0.
.
.
15activatedNote------Ifspecifiedvalueisnotreached:Evaluationdisplayfield3Page28-68seealsoPage28-69---Ifspecifiedvalueisreached:-Pressbutton.
RapidDataTransferHELPSelectfunctionXXIndicatedondisplay(selectfunction)Page78of82Ignitionsystem,checking1/17/2006http://127.
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1428-68Evaluationdisplaygroup014,displayfield3Displayfield:3PossiblecauseCorrectiveactiongreaterthan15SparkplugfaultySparkplugconnectorfaultyIgnitioncoilorpoweroutputstagefaulty-Checksparkplugandignitioncablewithconnector-CheckignitioncoilPage28-5.
-CheckpoweroutputstagesPage28-15FuelinjectorfaultyCrankshafthousingleakingCompressionofoneormorecylindersweak-CheckfuelinjectorsPage24-48-Checkhosesetupofcrankcaseventilationforsecureseatingandproperseal.
-CheckcompressionpressurePage79of82Ignitionsystem,checking1/17/2006http://127.
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1428-69Thefollowingmeasuringvalueblocksdisplaymisfiringofindividualcylinders:Displayfields1234DisplayGroup015:Misfirerecognitionfromcylinder1,2and3Displayxxxxxxxxx---IndicatesAmountofmisfirescylinder1Amountofmisfirescylinder2Amountofmisfirescylinder3MisfirerecognitionWorkrangeactivatedlockedSpecifiedvalue0.
.
.
150.
.
.
150.
.
.
15activatedNoteIfspecificationisnotobtained:EvaluationPage28-71.
---Page80of82Ignitionsystem,checking1/17/2006http://127.
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1428-70Displayfields1234DisplayGroup016:Misfirerecognitionfromcylinder4,5and6Displayxxxxxxxxx---IndicatesAmountofmisfirescylinder4Amountofmisfirescylinder5Amountofmisfirescylinder6MisfirerecognitionWorkrangeactivatedlockedSpecifiedvalue0.
.
.
150.
.
.
150.
.
.
15activatedNoteIfspecificationisnotobtained:EvaluationPage28-71.
---Page81of82Ignitionsystem,checking1/17/2006http://127.
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1428-71Evaluationdisplaygroups015and016Displayfield:1,2and3frommeasuringvalueblock15and16PossiblecauseCorrectiveactiongreaterthan15SparkplugfaultySparkplugconnectorfaultyIgnitioncoilorpoweroutputstagefaulty-Checksparkplugandignitioncablewithconnector-CheckignitioncoilPage28-5.
-CheckpoweroutputstagesPage28-15FuelinjectorfaultyCheckcompressionofoneormorecylinderweak-CheckfuelinjectorsPage24-48-CheckcompressionpressurePage82of82Ignitionsystem,checking1/17/2006http://127.
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