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Motronic Injection System Servicing Guide

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0% found this document useful (0 votes)

70 views78 pages

Motronic Injection System Servicing Guide

Uploaded by

Bogdan Cojocaru

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

Motronic injection system, servicing Page 1 of 78

24-1

Motronic injection system,

servicing
Safety precautions

If special testing equipment is required during

road test, note the following:

WARNING!

Scan tools and testing devices must always

be secured on the rear seat and operated
from there by a second person.

If a scan tool or testing device were to be

operated from the passenger seat and there
were an accident involving activation of the
passenger-side airbag, the person seated
there could be seriously injured.

To reduce the risk of personal injury and/or

damage to the fuel injection and ignition system,
always observe the following:

Only disconnect and reconnect wires for

injection and ignition system, including test
leads, when ignition is turned off.

If engine is to be cranked at starting RPM

without starting (e.g. for compression testing),

http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.FU05.24.1 11/23/2002
Motronic injection system, servicing Page 2 of 78

disconnect connector from ignition coils and

from fuel injectors.

24-2

It is possible that the control module will

recognize a malfunction and store a DTC during
some tests. After completing all tests and
repairs, DTC memory should therefore be
checked and erased if necessary. Readiness
code must be generated after DTC memory is
erased Page 01-82 .

Always switch ignition off before cleaning

engine.

The battery should only be disconnected and

reconnected when the ignition is turned off,
since otherwise the Engine Control Module
(ECM) can be damaged.

WARNING!

Fuel system is under pressure! Place a cloth

around the connection point before opening
system. Then release pressure by carefully
loosening connection point.

24-3

Rules of cleanliness

When working on the fuel supply or fuel injection

systems, the following "6 rules of cleanliness"
should be carefully observed:

Thoroughly clean all connections and the

surrounding area before disconnecting.

Place parts that have been removed on a clean

surface and cover. Use lint-free cloths only!

Carefully cover opened components or seal

them if repairs are not carried out immediately.

Only install clean components: Only unpack

replacement parts immediately prior to
installation. Do not use parts that have been
stored loose (in tool boxes etc.)

When the system is open: Do not work with

compressed air if it can be avoided. Do not
move vehicle unless absolutely necessary.

Disconnected electrical harness connectors:

Protect from dirt and moisture. Be sure harness
connector is dry before connecting.

24-4

Technical data

Engine identification ATQ (2.8 L / 5V/ 147 kW-engine)

Idle speed

Engine speed cannot be adjusted, it is regulated by idle 720 to 820 RPM (front wheel drive)
stabilization
630 to 730 RPM (all wheel drive)
Engine speed (RPM) limitation

via fuel injector shut-off about 6800 RPM

Fuel pressure at idle speed Vacuum hose
connected
3.2 to 3.8 bar
Vacuum hose

disconnected 3.8 to 4.2 bar

Residual pressure after 10 min. cold engine about 2.2 bar positive pressure
warm engine about 3.0 bar positive pressure
Fuel injectors Injection stream Dual-hole nozzle / same for all
injectors
Injection quantity (30 90 to 125 ml.
s)
Resistance

(room temperature) 1) 13.5 to 15.5

1) With an engine at normal operating temperature, the resistance of the fuel injectors increases by approx. 4 to 6

24-5

Component locations, overview

Notes:
Other component Locations Fig. 7 , page
Page 24-11 up to Fig. 12 , page Page
24-13 .
Component Locations without illustration:
A - Oxygen Sensor (O2S) Behind Three
Way Catalytic Converter (TWC) -G130-
with Oxygen Sensor (O2S) Heater 1 -
Z29-
Bank 2, sensor 1
Accessible from below after vehicle has
been lifted
B - Oxygen Sensor (O2S) 2 Behind Three
Way Catalytic Converter (TWC) -G131-
with Oxygen Sensor (O2S) Heater 2 -
Z30-
Bank 2, sensor 2
Accessible from below after vehicle has
been lifted
C - Leak Detection Pump (LDP) -V144-
Below the rear left wheelhousing liner

24-6

1 - 4-pin harness connector

for Oxygen Sensor (O2S) behind Three
Way Catalytic Converter (TWC) -G130-
and Oxygen Sensor (O2S) Heater 1 -Z29-
(bank 1 sensor 2)
green
2 - 4-pin harness connector
for Oxygen Sensor (O2S) 2 behind Three
Way Catalytic Converter (TWC) -G131-
and Oxygen Sensor (O2S) Heater 2 -Z30-
(bank 2 sensor 2)
brown
3 - 4-pin harness connector
for Heated Oxygen Sensor (HO2S) -G39-
before catalytic converter and Oxygen
Sensor (O2S) Heater -Z19- (bank 1 sensor
1)
Black
4 - 3-pin harness connector
for Knock Sensor (KS) 1 -G61-
blue

24-7

5 - Secondary Air Injection (AIR) solenoid

valve -N112-
6 - Intake Air Temperature (IAT) sensor -G42-
7 - 4-pin harness connector
for Heated Oxygen Sensor (HO2S) 2 -
G108- before catalytic converter and
Oxygen Sensor (O2S) 2 Heater -Z28-
(bank 2 sensor 1)
Black
8 - 3-pin harness connector
for engine speed (RPM) sensor -G28-
gray
9 - 3-pin harness connector
for Knock Sensor (KS) 2 -G66-
blue

24-8

10 - E-box in plenum chamber

Motronic Engine Control Module (ECM) -
J220-
Secondary Air Injection (AIR) Pump Relay -
J299- Fig. 10 , page Page 24-12
11 - Valve -2- for camshaft adjustment -N208-
12 - Camshaft Position (CMP) sensor 2 -G163-
Bank 1
13 - Heated Oxygen Sensor (HO2S) -G39-
before catalytic converter with Oxygen
Sensor (O2S) Heater -Z19-
Bank 1, sensor 1
14 - Ground connection
on the engine bracket, right side
15 - Mass Air Flow (MAF) sensor -G70-
Checking Page 24-56
16 - Evaporative Emission (EVAP) canister
purge regulator valve -N80-

24-9

17 - Engine Coolant Temperature (ECT) sensor

-G62-
for Engine Control Module (ECM)
At coolant line behind cylinder head engine
bank 1
with Engine Coolant Temperature (ECT)
Sensor -G2-
Checking Page 28-23
If necessary, release pressure in cooling
system before removing
18 - Throttle valve control module -J338-
With throttle drive (power accelerator
actuation) -G186-, angle sensor -1- for
throttle drive (power accelerator actuation)
-G187-, and angle sensor -2- for throttle
drive (power accelerator actuation) -G188-
19 - Intake Manifold Change-Over Valve -N156-
20 - Fuel pressure regulator
21 - Engine Speed (RPM) sensor -G28-
in transmission housing via ring gear
Checking Page 28-19

24-10

22 - Camshaft Position (CMP) sensor 2 -G40-

Bank 2
23 - Heated Oxygen Sensor (HO2S) 2 -G108-
before catalytic converter with Oxygen
Sensor (O2S) 2 Heater -Z28-
Bank 2, sensor 1
24 - Knock Sensor (KS) 2 -G66-
25 - Ignition coils (-N-, -N128-, -N158-)
with power output stage -N122-
26 - Knock Sensor (KS) 1 -G61-
27 - Fuel injectors -N30- through -N33-
,Cylinder 5/6 Fuel Injector -N83-, -N84-
28 - Valve -1- for camshaft adjustment -N205-
29 - Secondary Air Injection (AIR) pump
motor-V101-

24-11

Fig. 7 Component location, fault light for power accelerator

activation -K132-

Fig. 8 Installation position, Throttle Position (TP) sensor -G79-

and sender 2 for accelerator pedal position -G185-

24-12

Fig. 9 Component location Brake Light Switch -F- and Brake

Vacuum Vent Valve Switch For Cruise Control/Diesel Fuel
Injection, Clutch Vacuum Vent Valve Switch -F36-
1 - Clip
2 - Brake Light Switch -F-, Brake Vacuum Vent Valve Switch For Cruise
Control/Diesel Fuel Injection -F47-
3 - Clutch vacuum vent valve switch -F36-

Note:

In order to assure sufficiently secure fitting, switches must not be installed

more than once.

Adjusting switch:

Repair Manual, Brake System, ABS, ABS/EDL, Repair Group 46

Fig. 10 Component location for Secondary Air Injection (AIR)

Pump Relay -J299-

Secondary Air Injection (AIR) Pump Relay -J299- (arrow) in 3-pin relay
carrier in E-box, plenum chamber.

24-13

Fig. 11 Component locations Fuel Pump (FP) Relay -J17-

Fuel Pump (FP) Relay -J17- is located at position 4 of central electrics in

driver's footwell, left.

Fig. 12 Component location of Data Link Connector (DLC)

Data Link Connector (DLC) in knee bolster on driver's side.

24-14

Air filter, disassembling and assembling

1 - Cover
2 - Air duct
to metering unit
3 - Mass Air Flow (MAF) sensor -G70-
4 - 10 Nm
5 - Connection hose
6 - Seal
7 - Air filter, upper portion
8 - Rubber grommet
9 - Filter element
10 - Air filter, lower portion

24-15

Intake manifold change-over components,

removing and installing

1 - Vacuum setting element

2 - Compression spring
3 - Rotary change-over valve
4 - Intake Manifold
5 - Check-valve
Installed position: blue side toward Y-piece
6 - Y-piece
7 - Intake manifold change-over valve -N156-

24-16

8 - 10 Nm
9 - Securing plate
10 - Rubber grommet
11 - Spacer sleeve
12 - Washer
conical side toward intake manifold
13 - Seal
Replace if damaged
14 - Seal
for rotary change-over valve
Replace if damaged
15 - 6 Nm

24-17

Wire and component test using

VAG1598/31 test box

Notes:

VAG1598/31 test box is designed so that it can

be simultaneously connected to the wiring
harness at the Engine Control Module (ECM)
and also to the ECM itself.

This is advantageous because electronic

engine control remains fully functional (e.g.
measurement of signals with engine running)
when the test box is attached.

Relevant test procedures note whether Engine

Control Module (ECM) should also be
connected to the test box or not.

Always use VAG1594A connector test kit to

attach measurement devices (e.g. VAG1527B
voltage tester, VAG1526 multimeter etc.).

CAUTION!

To reduce the risk of damaging electronic

components, set the tester to the approprate
test range and observe test requirements
before connecting test leads.

24-18

Special Tools and Equipment

VAG1598/31

Procedure

- Switch ignition off.

- Pull off rubber seal of plenum chamber cover in direction of arrow.

- Remove cover -1- toward front.

24-19

- Remove Heater Core E-box cover -arrows-.

- Using a screwdriver, carefully pry off retaining bracket (arrow).

- Disengage locking lugs and remove control module connector.

Note:

Adaptation values are erased when connector is disconnected from the

Engine Control Module (ECM), DTC memory content remains intact.

24-20

- Connect VAG1598/31 test box to connector of wiring harness. Ground

(GND) clip at test box (not visible in illustration) must be connected to
Ground (GND). Relevant test procedures note whether Engine Control
Module (ECM) should also be connected to the test box.
- Perform test as described in relevant repair sequence.

Important note:

After re-connecting the Engine Control Module (ECM), the following work
steps must be performed:

- Check DTC memory and erase it if necessary Page 01-15 .

- Perform adaptation of the Throttle Valve Control Module -J338- Page

24-142 .

Note:

In the first adaptation phase during engine basic setting, it is possible that
idle will be rough and vehicle may shake lightly in drive mode.

24-21

Engine Control Module (ECM), replacing

Special Tools and Equipment

VAS5051 with VAG5051/1

or
VAG1551 with VAG1551/3B

Removing

- Connect VAS5051 tester or VAG1551 scan tool and select the control
module for engine electronics using "address word" 01 Page 01-9 .
Ignition must remain switched on for this.

3B0907551BA 2.8l V6/5V G 0003 VAG1551 Scan Tool (ST) display indicates control module identification,
Coding 07252 WSC 12345
e.g.:

- First, always allow display of control module identification and print it

out Page 01-11 .
- Compare coding with coding versions Page 01-73 .
- Switch ignition off.

24-22

- Pull off rubber seal of plenum chamber cover in direction of arrow.

- Remove cover -1- toward front.

- Remove Heater Core E-box cover -arrows-.

24-23

- Using a screwdriver, carefully pry off retaining bracket (arrow).

- Disengage locking lugs and remove control module connector.
- Remove Engine Control Module (ECM).

Installing

Installation is reverse of removal, noting the following:

Important note:

After installing new Engine Control Module (ECM), the following work
steps must be performed:

- Check DTC memory and erase it if necessary Page 01-15 .

- Perform adaptation of the Throttle Valve Control Module -J338- Page

24-142 .

24-24

- Observe notes for coding new Engine Control

Module (ECM) Page 01-71 .

- For vehicles with cruise control (discernable at

steering column), switch this free in ECM:

Repair Manual, Electrical Equipment, Repair

Group 01; On Board Diagnostic (OBD) of cruise
control system; Cruise control system, checking

- Adapt immobilizer to Engine Control Module

(ECM):

Repair Manual, Electrical Equipment, Repair

Group 01; On Board Diagnostic (OBD) of
immobilizer after replacing Engine Control
Module (ECM)

- For vehicles with automatic transmission, the

kick down function must be learned Page 24-
161 .

- Generate readiness code Page 01-82 .

Note:

In the first adaptation phase during engine basic

setting, it is possible that idle will be rough and
vehicle may shake lightly in drive mode.

24-25

Idle speed (RPM), checking

Special Tools and Equipment

VAS5051 with VAG5051/1

or
VAG1551 with VAG1551/3B

Test requirements:
Exhaust system free of leaks.

Coolant Temperature at least 80 C.

Electrical consumers switched off (radiator fan must NOT run during
test).
A/C switched off.

No pressure gauge connected.

Vehicles with automatic transmission Selector lever in P or N.

24-26

Notes:

Idle speed cannot be adjusted.

Idle speed is checked during basic setting of

the engine.

During basic setting, the Evaporative Emission

(EVAP) canister purge regulator valve (EVAP
valve -N80-) is closed and the A/C compressor
is switched off

Test sequence

- Check DTC Memory Page 01-15 . There must

not be any DTCs stored, repair malfunctions if
necessary, erase DTC memory, switch engine
off and start again, road test vehicle and check
DTC memory again as a control measure.

- Let engine continue to run at idle.

CAUTION!

The electric cooling fan must not run.

Rapid data transfer HELP When indicated on display:

Select function XX
- Press buttons -0- and -4- to select "Initiate basic setting" and press -Q-
button to confirm input.

24-27

Basic Setting Q When indicated on display:

Input display group number XXX
- Press buttons -0-, -5- and -6- to select "display group number 056" and press -Q-
button to confirm input.

System in Basic Setting 56 When indicated on display:

1 2 3 4
- Check whether the engine speed in display field 1 (actual engine speed) is within
tolerated range.

Display fields
1 2 3 4
Display group 056: Idle stabilization with engine at idle and operating temperature
Display xxx /min xxx /min x.x % XXXXX
Indicated Engine speed (actual) Engine speed Idle control Operating conditions
(specified)
Torque
change
Specified 720 to 820 RPM 1) 770 RPM 1) -5 to 5 % 00000
value
630 to 730 RPM 2) 680 RPM 2)
Notes If specified value is not obtained Significance of
Page 24-29 numbers
Page 24-29

1) Front Wheel Drive Vehicles

2) All-Wheel Drive Vehicles

24-28

Notes:

Engine speed in display field 1 (actual engine

speed) is the current engine speed.

Engine speed in display field 2 (specified

engine speed) is a theoretical engine speed
calculated by the ECM.

At idle, the ECM always attempts to adapt the

engine speed (actual) to the specified engine
speed (specified).

This means that the engine speed (actual) must

always approximately match the engine speed
(specified) at idle.

Display fields 3 and 4 provide information, but

are not relevant for checking idle speed.

If specified value is obtained:

- Press button.

Rapid data transfer HELP Indicated on display (function selection):

Select function XX
If specified value is not obtained:

- Check DTC memory again Page 01-15 .

- If DTC memory was erased, readiness code must be re-generated

Page 01-82 .

24-29

If idle speed is too high or low and there are

no DTCs in DTC memory, the following tests
(marked with dots) must be performed:

False air in intake air system, checking

Page 24-64 .

Throttle valve control module, checking

Page 24-141 .

Evaporative Emission (EVAP) canister purge

regulator valve always open, checking
Page 24-128 .

Perform adaptation of throttle valve control

module Page 24-142 .

Significance of 5 digit indication of display group 056

x x x x x Display field 4
0 A/C compressor

0 = A/C compressor off

1 = A/C compressor on
0 Driving mode selected

0 = selector lever in P or N

1 = selector lever in 2/3/4/D/R

0 A/C readiness maximum heating/cooling power
0 Indication always 0
0 Indication always 0

24-30

Fuel pressure regulator and residual

pressure, checking

Note:

Fuel pressure regulator regulates fuel pressure

according to intake manifold pressure. This
ensures that the pressure drop at the fuel
injectors remains the same for each speed and
load range of the engine.

Special Tools and Equipment

VAG 1318 with VAG 1318/7 adapter, VAG 1318/8 pressure hose with
connectors and VAG 1318/15 adapter

Test requirements:
Fuel Pump (FP) OK, checking Page 24-49 .

Fuel Pump (FP) OK, checking:

Repair Manual, Fuel Supply System, Repair Group 20; Fuel supply
Front Wheel Drive or fuel supply - All Wheel Drive

Fuel filter OK

Battery voltage at least 12.7 V

Vehicles with automatic transmission Selector lever in P or N.

24-31

WARNING!

Fuel system is under pressure! Place a cloth

around the connection point before opening
system. Then release pressure by carefully
loosening connection point.

- Remove engine cover (arrows).

Checking system pressure

- Connect VAG1318 pressure gauge using adapters

VAG1318/7, /1318/8 pressure hose with connectors and 1318/15
adapter in supply line.
- Disconnect vacuum hose from pressure regulator to intake manifold at
pressure regulator and seal line.

Note:

If fuel should escape at the vacuum connection of the pressure regulator

during the following pressure test, replace pressure regulator.

- Start engine and let run at idle.

24-32

- Measure fuel pressure.

Specification: 3.8 to 4.2 bar

- If the specified value is not reached, replace

pressure regulator on a trial basis and repeat
pressure test.

- If the specified value is not reached again, check

Fuel Pump (FP) or supply line for damage (e.g.
pinched areas) and replace if necessary.

- If the specified value is exceeded, check return

line for damage (e.g. pinched areas) and replace
if necessary.

Note:

During the following test, the engine must not run

for an unnecessarily long period of time with the
vacuum hose removed. Otherwise, the higher
fuel pressure can cause enrichment of the fuel to
air ratio, which under some circumstances can
cause the oxygen sensor control limits to be
exceeded, causing a DTC to be stored.

- Start engine and let run at idle.

- Switch of electrical consumers (A/C system

etc.).

- Connect vacuum hose at pressure regulator

while observing pressure drop at pressure
gauge.

24-33

- Fuel pressure must drop by approx. 0.5 bar

when connecting the vacuum hose.

If the pressure change does not occur, the

following tests must be performed:

Check vacuum hose for tears and

damage.

Check vacuum hose at intake manifold for

throughput by disconnecting from pressure
regulator and blowing into it.

- If no leaks can be detected and if the vacuum

hose has throughput, replace the pressure
regulator.

Checking residual pressure

- Residual pressure 10 minutes after switching

engine off (minimum pressure).

Specified value with a cold engine: approx.

2.2 bar

Specified value with the engine at operating

temperature: approx. 3.0 bar

Note:

Pressure increase for an engine at operating

temperature limited by the fuel expansion is
normal.

24-34

- Start engine and let run at idle.

- Wait until pressure has dropped, and then switch off ignition.
Simultaneously close shut-off valve of VAG1318 pressure gauge (lever
perpendicular to direction of flow -arrow-).

The following malfunction are possible if the pressure does not drop:

There is a leak in the threaded connection between the pressure

gauge and the fuel supply line
There is a leak at the supply line at fuel tank.
There is a leak in the check valve in the Fuel Pump (FP).

Repair Manual, Fuel Supply System, Repair Group 20; Fuel supply -
Front Wheel Drive or fuel supply - All Wheel Drive

Note:

Pressure gauge displays the pressure behind the stopcock "intake

manifold side" after the stopcock is closed (in direction of fuel injector, fuel
pressure regulator). If the pressure drops in front of the stopcock (in
direction of fuel tank), the device cannot detect it. For this reason, the
center of this page states "If the pressure does not drop...".

24-35

The following malfunctions are possible if the

pressure drops again:

Fuel pressure regulator faulty

Fuel injectors not properly sealed

Threaded connections of pressure gauge

behind stopcock is not properly sealed.

Note:

Close stopcock for removing the pressure gauge,

loosen threaded connection at VAG1318/15
adapter and let excess fuel escape into catch
reservoir by opening stopcock.

24-36

Fuel injectors, checking

Special Tools and Equipment

VAG1526A
VAG1527B
VAG1594A
VAG1598/31

24-37

Checking internal resistance

- Remove engine cover (arrows).

- Disconnect harness connector at the fuel injector to be tested.

- Connect multimeter at valve for resistance measurement.

Specification: 13.5 to 15.5

With an engine at operating temperature, the resistance increases by

approx. 4 to 6 .

If specified value is not obtained:

- Replace fuel injector Page 24-43 .

24-38

Checking voltage supply

Test requirements:

Fuel Pump (FP) OK, checking Page 24-

49 .

Fuse for fuel injectors OK

Electrical Wiring Diagrams, Troubleshooting &

Component Locations binder

- Disconnect harness connector at the fuel

injector to be tested.

- Connect VAG1527B voltage tester as follows:

Harness connector Measure to

Terminal
1 Engine Ground (GND)
- Switch ignition on.
LED must light up.

If LED does not light up:

- Check wire connection between terminal 1 and fuse for injector valves
for open circuit:

Electrical Wiring Diagrams, Troubleshooting & Component Locations

binder

24-39

- Repair open circuit if necessary.

If LED lights up:

Checking activation

Test requirement:

Internal resistance of valve OK

- Slide back rubber grommet of fuel injector connector (arrow), but leave
connector connected.
- Connect VAG1527B voltage tester between sockets 2 (signal) and 1
(B+).
- Operate starter briefly (engine can also start).
LED must blink.

Note:

Voltage testers do not go out completely during low current pick-up

between activations by the ECM, but rather continue to glow a little and
then get slightly brighter during activation.

24-40

If LED does not blink:

- Connect VAG1598/31 test box at wiring harness

to ECM, do not connect ECM Page 24-17 .

- Check the following wire connections for open circuit and short circuit
to Ground (GND) and B+:

Cylinder Fuel injector harness connector VAG1598/31 test box

Terminal Socket
1 2 96
2 2 112
3 2 88
4 2 97
5 2 113
6 2 89
- Repair open circuit or short circuit if necessary.

If wire connection is OK:

- Replace Engine Control Module (ECM) Page 24-21 .

24-41

Fuel rail with fuel injectors, disassembling

and assembling

1 - Fuel distributor
2 - to T-piece
3 - Retaining clip
Check for secure fitting
4 - O-ring
Removing and installing Page 24-43
Always replace
Coat with clean engine oil
5 - Fuel pressure regulator

24-42

6 - O-ring
Removing and installing Page 24-43
Always replace
Coat with clean engine oil
7 - Fuel injectors -N30- through -N33-
,Cylinder 5/6 Fuel Injector -N83-, -N84-
Removing and installing Page 24-43
8 - Retaining clip
Make sure clip is correctly seated on fuel
injector and fuel rail

24-43

Fuel injectors, removing and installing

- Remove engine cover (arrows).

- Remove intake air hose between Mass Air Flow (MAF) sensor and
intake air elbow.
- Remove all harness connectors to injectors.
- Disconnect vacuum hose from fuel pressure regulator.
- Expose wires at fuel distributor.

- Unscrew fuel distributor from intake manifold (arrows) .

- Remove fuel distributor with injectors from intake manifold
simultaneously upward and set aside in rear of engine compartment on
a clean cloth.

WARNING!

Fuel system is under pressure! Place a cloth around the connection

point before opening system. Then release pressure by carefully
loosening connection point.

24-44

- Disengage retaining clip and remove fuel

injector.

Note:

Fuel lines must be disconnected before replacing

fuel distributor.

Installation is reverse of removal, noting the

following:

Remove O-rings at all opened connections.

(Never remove plastic cap from valve head
to replace front O-ring - pry O-ring off over
plastic cap).

Lightly lubricate O-rings with clean engine

oil.

Make sure fuel injectors are in place and

seated correctly

Check clip for unobstructed fitting.

Place fuel rail with secured fuel injectors

onto intake manifold, and apply uniform
pressure to press it in.

Tightening torque

Component Nm
Fuel distributor at intake manifold 10

24-45

Injection quantity, proper seal and spray

pattern of fuel injectors, checking

Special Tools and Equipment

VAG1348/3A with VAG1348/3-2

VAG1594A
VAG1598/31
VAG1602
VAS5051 with VAG5051/1
- or
VAG1551 with VAG1551/3B

24-46

Test requirement:

Fuel pressure OK, checking Page 24-30 .

Test sequence

- Remove fuel distributor including fuel injectors

from intake manifold Page 24-43 . Fuel lines
remain connected.

- Connect VAG1598/31 test box at wiring harness

to ECM, do not connect ECM Page 24-17 .

- Bridge terminals 1 and 65 at test box using

adapter cables from VAG1594A connector test
kit (this step supplies Ground -GND- to one side
of relay coil for Fuel Pump -FP- relay).

Note:

Fuel Pump (FP) relay is supplied with B+ via the

central electric (terminal 30). Fuel Pump (FP)
relay receives minus via the cable bridge in test
box. The Fuel Pump (FP) is now running
constantly.

24-47

Checking Proper Seal

- Check proper seal of fuel injectors (visual

inspection). With Fuel Pump (FP) running, only 1
to 2 drops per minute may drip out per injector.

- If fuel loss is greater, stop Fuel Pump (FP) from

running (disconnect cable bridge) and replace
faulty fuel injector Page 24-43 .

Checking Injection Quantity

- Insert fuel injector to be tested in a measuring glass from VAG1602

injection quantity test device.

- Connect one terminal of fuel injector to engine Ground (GND) using an

adapter cable and an alligator clip from VAG1594A connector test kit.
- Connect the second terminal of fuel injector to B+ using VAG1348/3A
remote control, VAG1348/3-2 adapter cable and assisting cable.

24-48

- Bridge terminals 1 and 65 at test box using wires

from VAG1594A adapter test kit.

Fuel Pump (FP) must run.

- Operate VAG1348/3A remote control for 30

seconds.

- After all three fuel injectors of one cylinder row

have been activated, place measuring glasses
on an even surface.

Specified value for each fuel injector: 90 to

125 ml.

- If measured value of one or more fuel injectors

is outside of specified range, switch Fuel Pump
(FP) off (disconnect cable bridge) and replace
faulty fuel injector Page 24-43 .

- Repeat test at fuel injectors of second cylinder

row.

- If the measured values of all fuel injectors are

outside the specified range, check fuel pressure
Page 24-30 .

Note:

Also check spray pattern when checking injection

quantity. Spray pattern must be the same for all
injectors

- Install fuel injectors together with fuel distributor

Page 24-44 .

24-49

Fuel Pump (FP) relay -J17- and activation,

checking

Special Tools and Equipment

VAG1526A
VAG1594A
VAG1598/31
VAS5051 with VAG5051/1
- or
VAG1551 with VAG1551/3B

24-50

Voltage is supplied to the Fuel Pump (FP) and

several components of the injection system via
the Fuel Pump (FP) relay -J17-.

Engine must be turning for Fuel Pump (FP) relay

-J17- to close. This means that the relay does
not receive Ground (GND) (via ECM) until the
ECM recognizes RPM signals.

Note:

Fuel Pump (FP) relay is located at position 4 of central electrics in driver's

footwell, left.

Test requirement:
Battery voltage at least 12.7 V

24-51

Function test of Fuel Pump (FP) relay

- Remove driver-side storage compartment.

Repair Manual, Body-Interior, Repair Group

68; Instrument Panel; Removing Driver-Side
Storage Compartment

- Connect VAS5051 tester or VAG1551 scan tool

and select the control module for engine
electronics using "address word" 01 Page 01-
9.

Ignition must remain switched on for this.

- Initiate output Diagnostic Test Mode Page 01-

56 and activate Evaporative Emission (EVAP)
canister purge regulator valve -N80-.

Fuel Pump (FP) relay (at position 4 of central electrics in driver's

footwell, left) must trigger and Fuel Pump (FP) must run.

A - If relay does not trigger:

- Check voltage supply of Fuel Pump (FP) relay Page 24-52 .

- Checking activation of Fuel Pump (FP) relay Page 24-52 .

24-52

B - If relay triggers, but Fuel Pump (FP) does not

run:

- Check voltage supply for Fuel Pump (FP) and

components (via Fuel Pump -FP- relay) Page
24-54 .

Check voltage supply of Fuel Pump (FP)

relay

- Remove Fuel Pump (FP) relay.

- Connect multimeter to terminal 17 of relay socket and Ground (GND)

for voltage measurement.
Specification: approx. battery voltage

If specified value is not obtained:

- Replace central electrics.

Checking activation of Fuel Pump (FP) relay

- Switch ignition off.

- Connect VAG1598/31 test box at wiring harness to ECM, do not
connect ECM Page 24-17 .
- Bridge terminals 1 and 65 at test box using wires from VAG1594A
adapter test kit.

24-53

Fuel Pump (FP) relay (at position 4 of central electrics in driver's

footwell, left) must trigger.

If relay triggers now, but didn't during output DTM:

- Replace Engine Control Module (ECM) Page 24-21 .

If relay does not trigger:

- Remove cable bridge.

- Remove Fuel Pump (FP) relay.

- Connect multimeter to terminal 19 of relay socket and Ground (GND)

for voltage measurement.
Specification: approx. battery voltage

If specified value is not obtained:

- Check wire connections.

Electrical Wiring Diagrams, Troubleshooting & Component Locations

binder

24-54

If specified value is obtained:

- Check the following wire connection for open circuit and short circuit to
Ground (GND) and B+:

Central electric VAG1598/31 test box

in driver-side footwell, left, position 4

Terminal

Socket
16 65

- Repair open circuit or short circuit if necessary.

If no malfunctions are detected:

- Replace Fuel Pump (FP) relay -J17-.

- Re-connect Engine Control Module (ECM).

Check voltage supply for Fuel Pump (FP) and components

- Remove fuses S228, S229, and S234 (positions 28, 29, and S234)
from fuse holder.
- Initiate output Diagnostic Test Mode Page 01-56 and activate
Evaporative Emission (EVAP) canister purge regulator valve -N80-.

24-55

- Connect multimeter for voltage measurement to

Ground (GND) and to one terminal of the
following fuses in the fuse holder.

Fuse Specified value at one of the

terminals
S228 approx. battery voltage
S229 approx. battery voltage
S234 approx. battery voltage

If specified values are not obtained:

- Repeat test at another terminal of fuse socket.

If specified values are not obtained again:

- Check wire connections.

Electrical Wiring Diagrams, Troubleshooting &

Component Locations binder

If no malfunctions are detected:

- Replace Fuel Pump (FP) relay -J17-.

- Re-insert the fuses.

24-56

Mass Air Flow (MAF) sensor -G70-,

checking

Special Tools and Equipment

VAG1526A
VAG1594A
VAG1598/31
VAS5051 with VAG5051/1
- or
VAG1551 with VAG1551/3B

24-57

Test requirements:

Coolant Temperature at least 80 C.

Electrical consumers switched off (radiator

fan must NOT run during test).

A/C switched off.

Fuse for Mass Air Flow (MAF) sensor OK

Electrical Wiring Diagrams, Troubleshooting &

Component Locations binder

Checking function

- Connect VAS5051 tester or VAG1551 scan tool

and select the control module for engine
electronics using "address word" 01 Page 01-
9.

Engine must run at idle for this.

Rapid data transfer HELP When indicated on display:

Select function XX
-
Press buttons -0- and -4- to select "Initiate basic setting" and press -Q-

button to confirm input.

Note:

During basic setting, the Evaporative Emission (EVAP) canister purge

regulator valve (EVAP valve -N80-) is closed and the A/C compressor is
switched off

24-58

Basic Setting Q When indicated on display:

Input display group number XXX
- Press buttons -0-, -0- and -2- to select "display group number 002" and press -Q-
button to confirm input.

System in Basic Setting 2 When indicated on display:

1 2 3 4
- Check specified values for load detection in display fields 3 and 4.

Display fields
1 2 3 4
Display group 002: Air mass taken in with engine at idle and operating temperature
Display xxx /min xx.x % x.x ms xxx.x g/s
Indicated Engine speed Load mean injection time Air mass
(RPM)
Functional 630 to 6800 12 to 100 1.0 to 20.0 ms 1.0 to 150 g/s
range RPM %
Specified 720 to 820 12.0 to 1.0 to 4.0 ms 1.0 to 5.0 g/s
value RPM1) 26.0 %

630 to 730
RPM2)
Notes --- --- If specified value is not obtained: If specified value is not obtained:
Evaluation display field 3 Page 24- Evaluation display field 4 Page 24-
59 60

1) Front Wheel Drive Vehicles

2) All-Wheel Drive Vehicles

24-59

If specified values are obtained:

- Press button.

Rapid data transfer HELP Indicated on display (function selection):

Select function XX

Evaluation display group 002

Display field: 3 Possible cause Corrective action

less than 1.0 Smaller values are only possible when driving in
ms deceleration mode
larger than 4.0 - Reduce load (A/C system/power
Engine under load due to power accessories.
ms steering/generator)

Poor idle (does not run on all cylinders) - Check spark plugs.
- Check fuel injectors Page 24-36

Throttle valve control module - J338- faulty - Check throttle valve control module Page
24-141

24-60

Evaluation display group 002

Display field: Possible cause Corrective action

4
smaller than large false air mass between intake manifold and Mass Air - Check intake system for leaks (false
1.0 g/s Flow (MAF) sensor air) Page 24-64
Voltage supply of Mass Air Flow (MAF) sensor or wire - Check voltage supply Page 24-61
connections to Engine Control Module (ECM)
larger than 5.0
Engine under load due to power accessories. - Reduce load (A/C system/power
g/s steering/generator)

Voltage supply of Mass Air Flow (MAF) sensor or wire - Check voltage supply Page 24-61
connections to Engine Control Module (ECM)

24-61

Voltage supply for Mass Air Flow (MAF)

sensor, checking

- Disconnect connector from Mass Air Flow (MAF)

sensor.

- Connect multimeter for voltage measurement as follows.

Harness connector Measure to

Terminal
3 Engine Ground (GND)
- Operate starter briefly.
Specification: approx. battery voltage

Note:

Voltage is supplied to Mass Air Flow (MAF) sensor from Fuel Pump (FP)
relay.

If specified value is not obtained:

- Check wire connection from terminal 3 of connector to Fuel Pump (FP)

relay via fuse for open circuit and short circuit to Ground (GND):

Electrical Wiring Diagrams, Troubleshooting & Component Locations

binder

24-62

- Repair open circuit or short circuit if

necessary.

- Connect multimeter to terminal 2 and terminal 3 of connector for

voltage measurement.
- Operate starter briefly.
Specification: approx. battery voltage

Note:

Ground (GND) from the ECM is present at terminal 2 of connector.

If specified value is not obtained:

- Check wire connections Page 24-63 .

- Connect multimeter to terminal 1 and terminal 2 of connector for

voltage measurement.
- Switch ignition on.
Specification: about 5 V

If specified value is not obtained:

- Check wire connections Page 24-63 .

24-63

Check wire connections for Mass Air Flow

(MAF) sensor

Note:

Signal wire is also checked during wire test.

- Connect VAG1598/31 test box at wiring harness

to ECM, do not connect ECM Page 24-17 .

- Check the following wire connections for open circuit and short circuit
to Ground (GND) and B+:

Harness connector VAG1598/31 test box

Terminal Socket
1 53
2 27
4 29
- Repair open circuit or short circuit if necessary.
- Also check all wires for short circuit to each other.

If wire connection is OK:

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

24-64

Intake air system, checking for leaks

(unmetered air)

Special tools and equipment

VAS5051 with VAG5051/1

or
VAG1551 with VAG1551/3B
Engine leak detection spray G 001 800 A1

Notes:
The negative pressure in the intake system sucks in the leak detection
spray with the unmetered air. Leak detection spray decreases ignition
quality and performance of the fuel mixture. This causes a reduction in
engine speed and a sharp increase of CO content.
It is absolutely necessary to follow the safety precautions listed on the
can.

24-65

Test sequence

- Connect VAS5051 tester or VAG1551 scan tool

and select the control module for engine
electronics using "address word" 01 Page 01-
9.

Engine must run at idle for this.

Rapid data transfer HELP When indicated on display:

Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block" and
press -Q- button to confirm input.

Read Measuring Value Block Q When indicated on display:

Input display group number XXX
- Press buttons -0-, -0- and -1- to select "display group number 001" and
press -Q- button to confirm input.

Read Measuring Value Block 1 Indicated on display: (1 thru 4 display fields)

1 2 3 4
- Make note of engine speed in display field 1.
- Spray intake system parts with engine leak detection spray in a
systematic manner.

24-66

If engine speed does not change:

- Press button.

Rapid data transfer HELP Indicated on display (function selection):

Select function XX
If engine speed decreases:

- Press button.
- Press buttons -0- and -6- to select "End output" and press -Q- button to
confirm input.
- Switch ignition off.
- Check sprayed part of intake system for leaks, and eliminate the error.

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