check engine AUDI A4 1999 B5 / 1.G ATW Engine Motronic Fuel Injection Syst

24-31

Note:

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
Select function XX

Indicated on display (function selection):
If specified value is not obtained:
- Check DTC memory again Page 01
-16
.
Pa
ge 34 of 81 Motronic fuel in
jection s
ystem, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU06.24.1

24-33

System pressure, 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

Test requirements:
Repair Manual, Fuel Supply System, Repair Group 20

VAG1318V.A.G 1318 with V.A.G 1318/11 adapter, V.A.G 1318/12 pressure
hose with connectors and V.A.G 1318/13 adapter Fuel Pump (FP) relay OK; checking Page 24
-53
.
Fuel Pump (FP) OK, checking: Fuel filter OK Battery voltage at least 12.7 V Vehicles with automatic transmission Selector lever in P or N.
Pa
ge 37 of 81 Motronic fuel in
jection s
ystem, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU06.24.1

24-34

Checking system pressure

- Open fuel filler flap briefly (pressure release).

WARNING!
Fuel system is under pressure! Before opening system, place rags
around the connection point. Then release pressure by carefully
loosening connection. - Remove engine cover (arrows).

- Open threaded connection (arrow) and catch exiting fuel using a rag.
- Connect VAG1318 pressure gauge in supply line using adapters
1318/11, 1318/12 and 1318/13.
Pa
ge 38 of 81 Motronic fuel in
jection s
ystem, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU06.24.1

24-35


- Open shut-off valve of pressure gauge. The lever points in the direction
of flow.
- Start engine and let run at idle.
- Measure fuel pressure.

Specification: about 3.5 bar positive pressure

- Disconnect vacuum hose at fuel pressure regulator.

Fuel pressure must rise to about 4.0 bar positive pressure.
- Switch ignition off.
- Check for proper seal and residual pressure by observing pressure
drop on pressure gauge.
After 10 minutes, there must be at least 2.5 bar positive pressure
Pa
ge 39 of 81 Motronic fuel in
jection s
ystem, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU06.24.1

24-36
If residual pressure sinks below 2.5 bar positive
pressure:

- Start engine and let run at idle.

If pressure does not drop now:
If pressure drops again:
If pressure does not drop now: - 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-).
- Observe pressure drop on pressure gauge.
- Test check-valve on Fuel Pump (FP).
- Open shut-off valve of pressure gauge. The lever points in the direction
of flow.
- Start engine and let run at idle.
- Wait until pressure has dropped, and then switch off ignition.
Simultaneously clamp return line (with blue marking) completely
closed.
- Replace fuel pressure regulator
Pa
ge 40 of 81 Motronic fuel in
jection s
ystem, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU06.24.1

24-39

Checking internal resistance

- Remove engine cover (arrows).
- Disconnect harness connector at the fuel injector to be tested.

If specified value is not obtained:
If specified value is obtained: - Connect multimeter at valve for resistance measurement.

Specification: 12 to 13 (at room temperature)
- Replace fuel injector.
- Check voltage supply
Pa
ge 43 of 81 Motronic fuel in
jection s
ystem, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU06.24.1

24-40

Checking voltage supply

Test requirements:

Fuse for fuel injectors OK

Electrical Wiring Diagrams, Troubleshooting &
Component Locations

Fuel Pump (FP) relay OK; checking Page 24
-53
.

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

If LED does not light up: - Connect VAG1527B voltage tester as follows:Harness connector
Terminal
Measure to
1 Engine Ground (GND)
- Switch ignition on.

LED must light up.
Pa
ge 44 of 81 Motronic fuel in
jection s
ystem, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU06.24.1

24-41

- Repair open circuit if necessary.
If LED lights up:

- Activation of fuel injectors, checking

Checking activation

Test requirement:

Internal resistance of valve OK

- Slide back rubber grommet of fuel injector
connector, but leave connector connected.

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. - Connect VAG1527B voltage tester between sockets 2 (signal) and 1
(B+).
- Operate starter briefly (engine can also start).

LED must blink.
Pa
ge 46 of 81 Motronic fuel in
jection s
ystem, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU06.24.1

24-42
If LED does not blink:

- Connect VAG1598/31 test box at wiring harness
to Engine Control Module (ECM), do not connect
ECM Page 24
-19
.

If wire connection is OK: - Check following wire connections for open circuit and short circuit to
Ground (GND) and B+: Cylinder
Fuel injector harness connector
Terminal
VAG1598/31 test box
Socket
1 2 96
2 2 89
3 2 97
4 2 88
- Repair open circuit or short circuit if necessary.
- Replace Engine Control Module (ECM) Page 24
-23
Pa
ge 47 of 81 Motronic fuel in
jection s
ystem, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU06.24.1

24-50

Test requirement:

Fuel pressure OK, checking Page 24
-33
.

Test sequence

- Remove fuel distributor including fuel injectors
from intake manifold Page 24
-46
. Fuel lines
remain connected.

- Connect VAG1598/31 test box at wiring harness
to Engine Control Module (ECM), do not connect
ECM Page 24
-19
.

Checking Proper Seal

- Bridge terminals 1 and 65 at test box using wires
from VAG1594A adapter test kit.

- Switch ignition on.


Fuel Pump (FP) must run.

- 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
Pa
ge 55 of 81 Motronic fuel in
jection s
ystem, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.FU06.24.1