engine AUDI A4 1995 B5 / 1.G AHA Engine Multiport Fuel Injection And Ignition System Repair Manual

Fuse for fuel injectors OK
Engine speed (RPM) sensor OK
Fuel pump relay OK
Pa
ge 131 of 166 Motronic Multi
port Fuel In
jection
(MFI
) and i
gnition s
ystem
11/23/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU03.24.1

24-108

Checking injection amount

- Insert injector to be tested into measuring glass of VAG1602 fuel
analyzer.
- Connect one terminal of injector being tested to engine ground using
test lead from VAG1594.

Note:
This step lets the fuel pump run without the engine running. The closed
throttle position switch must be closed during the test, or the selected fuel
injector will discharge fuel when it is actuated 5 times. - Connect second terminal of injector to B+ using VAG1348/3A remote
control, VAG1348/3-2 adapter wire and an auxiliary wire.
- Conduct output DTM, actuating cylinder 1 injector -N30- page 01
-51

(fuel pump must be running).
Pa
ge 138 of 166 Motronic Multi
port Fuel In
jection
(MFI
) and i
gnition s
ystem
11/23/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU03.24.1

24-110

Checking for leaks

- Conduct output DTM, actuating cylinder 1
injector -N30- page 01
-51
(fuel pump must be
running).

Note:
This step lets the fuel pump run without the
engine running. The closed throttle position
switch must be closed during the test, or the
selected fuel injector will discharge fuel when it is
actuated 5 times.

- Visually check injector for leaks.

With fuel pump running, only 1 to 2 drops can
drip in a minute (per injector).
If fuel loss is greater:

- Replace leaking injector
Installation of the injectors is in reverse order of
removal.

- Replace O-rings on all injectors and coat O-rings
lightly with clean engine oil.

Pa
ge 140 of 166 Motronic Multi
port Fuel In
jection
(MFI
) and i
gnition s
ystem
11/23/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU03.24.1

24-112

Checking

Note:
Shut-off valve of pressure tester must be open (lever parallel to direction
of flow).
Note:
For the following test, do not let the engine run unnecessarily with the
vacuum hose removed, since the higher fuel pressure causes enrichment
of the fuel air mixture. The richer mixture could exceed the O2S control
limits and therefore cause a DTC to be stored.
Note:
If, during the following pressure test, fuel leaks from the vacuum
connection of the fuel pressure regulator, replace the fuel pressure
regulator. - Connect pressure tester VAG1318 between fuel supply line and fuel
rail using adapters 1318/7, 1318/10 and 1318/13.
- Remove vacuum line from fuel pressure regulator (to intake manifold)
and block line (using VW 3093).
- Switch off all electrical consumers (rear defrost, A/C etc.).
- Start engine and let idle.
- Measure fuel pressure.
Pa
ge 144 of 166 Motronic Multi
port Fuel In
jection
(MFI
) and i
gnition s
ystem
11/23/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU03.24.1

24-114
If there is no leak and vacuum connection has no
obstruction:

- Replace fuel pressure regulator.

Checking residual pressure

- Check residual pressure 10 minutes after
shutting off engine.


Cold engine (min.): approx. 2.2 bar (31.9
psi)

Warm engine (min.): approx. 3.0 bar (43.5
psi)

Note:
The higher pressure with a warm engine, caused
by fuel expansion, is normal.
If the specified value is not attained:

- Start engine and, after fuel pressure has
increased, switch ignition off.

- Close shut off valve on VAG1318 pressure
tester.
Pa
ge 148 of 166 Motronic Multi
port Fuel In
jection
(MFI
) and i
gnition s
ystem
11/23/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU03.24.1

24-116

Evaporative Emissions (EVAP) canister
purge regulator valve, checking


WARNING!

Whenever carrying out work on the fuel
supply and/or fuel injection systems, read
and carefully follow the Cautions, Warnings,
and rules of cleanliness page 24-9 .

Note:
Component locations page 24
-1

Required special tools and test equipment

VAG1551 or VAG1552 Scan Tool (ST) with
VAG1551/3 adapter cable

Test conditions
Engine coolant temperature at least 80 C
(176 F)

Function check

- Connect VAG1551 or VAG1552 scan tool and
press buttons -0- and -1- to insert "Engine
Electronics" address word 01 (with engine
running at idle) page 01
-8 .
Pa
ge 151 of 166 Motronic Multi
port Fuel In
jection
(MFI
) and i
gnition s
ystem
11/23/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU03.24.1

24-117

- Press buttons -0- and -8- to select "Read
Measuring Value Block" function 08, and press -
Q- button to confirm input. Read Measurin
g Value Block
HELP
Input displa
y group number XXX

Indicated on display
- Press buttons -0-, -7- and -0- to input display group number 70 (070),
and press -Q- button to confirm input.
Read Measuring Value Block 70 1 2 3 4

Indicated on display (1-4 = display fields)
Note:
During this diagnosis there should not be any load placed on the engine,
otherwise the diagnosis is interrupted and must be started again. - Press button -4- to select "Basic Setting" function 04 (diagnosis for
EVAP canister purge regulator valve is initiated).
System in Basic Setting 70 1 2 3 4

Indicated on display (1-4 display fields)
If the diagnosis is initiated by the ECM, the display changes from "Test
OFF" to "Test ON" in display field 4.
Note:
If the display changes from "Test ON" to "Test OFF" during the test,
accelerate with a brief burst to repeat the test. - Continue to run engine at idle until "EVAP OK" is indicated in display
field 4.
Pa
ge 153 of 166 Motronic Multi
port Fuel In
jection
(MFI
) and i
gnition s
ystem
11/23/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU03.24.1

24-121

Checking EVAP canister purge regulator
valve voltage supply

Test conditions

Fuse for EVAP canister purge regulator
valve OK

- Disconnect harness connector from EVAP
canister purge regulator valve.

If LED test light does not light:
If wiring is OK: - Connect VAG1527B LED voltage tester between connector terminal 1
(B+) and engine Ground.
- Operate starter motor.
Specified value: LED must light up
- Check wiring for open circuit between connector terminal 1 and fuse,
according to wiring diagram; repair if necessary.

Specified value: 1.0 max.- Check fuel pump relay page 24
-95
.
Pa
ge 158 of 166 Motronic Multi
port Fuel In
jection
(MFI
) and i
gnition s
ystem
11/23/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU03.24.1

24-125

Voltage supply, checking

If LED tester does not light: - Disconnect harness connector for LDP -V144-.
- Connect VAG1527B LED voltage tester between connector terminal 3
(B+) and engine Ground.
- Start engine and run engine at idle.
LED must light up.
- Check fuse for LDP -V144-.
- Check wiring for open circuit between terminal 3 and fuse, according to
wiring diagram.

Specified value: max. 0.5 .- Check fuel pump relay and signal to relay page 24
-95
.
Pa
ge 162 of 166 Motronic Multi
port Fuel In
jection
(MFI
) and i
gnition s
ystem
11/23/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU03.24.1

24-126

Intake air system, checking for leaks


Required special tools and test equipment

VAG1551 or VAG1552 Scan Tool (ST) with
VAG1551/3 adapter cable
Engine leak detector spray G 001 800 A1

Notes:
If there are leaks, intake manifold vacuum will
draw in the leak detector spray with outside air.
The spray reduces the ability of the fuel/air
mixture to ignite, which causes a drop in engine
speed and a significant increase in CO-content.
Observe the safety precautions listed on the
container.

Checking

- Connect VAG1551 or VAG1552 scan tool and
press buttons -0- and -1- to insert "Engine
Electronics" address word 01 (with engine
running at idle) page 01
-8 .
Rapid data transfer
HELP
Select function XX

Indicated on display
Pa
ge 163 of 166 Motronic Multi
port Fuel In
jection
(MFI
) and i
gnition s
ystem
11/23/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU03.24.1