Computers and Control Systems: Service and Repair
COMPONENTS, REMOVING AND INSTALLING
NOTE:
- Fuel hoses in engine compartment must only be secured with spring type clips. The use of clamp or screw type clips is not permissible.
- The Engine Control Module (ECM) for the fuel injection and ignition system is equipped with Diagnostic Trouble Code (DTC) memory. Before carrying out troubleshooting, repairs or adjustment work, DTC memory, must be checked for stored codes that indicate malfunctions, and the vacuum connections must be checked (intake air leaks).
- Components marked with an asterisk (*) are checked via the On Board Diagnostic program. Refer to "On-Board Diagnostic/Checking Diagnostic Trouble Code Memory (Function 02)". Testing and Inspection
- Components marked with a double asterisk (**) are checked using the output Diagnostic Test Mode (DTM). Refer to "On-Board Diagnostic/Output Diagnostic Test Mode (Function 03)". Testing and Inspection
- For trouble-free operation of the electrical components, a battery positive voltage (B+) of at least 11.5 volts is necessary,
- Do not use sealants containing silicone. Particles of silicone drawn into the engine will not be burned in the engine and may damage the Heated Oxygen Sensor (HO2S) probe.
- Do not use contact sprays or similar agents in the area of the connector for HO2S probes. To function correctly, the HO2S probes require reference air, which they receive via the cable. If contact spray gets into the probe via this path it will lead to damage or sensor malfunctions.
- During some checks the ECM will recognize test conditions as a problem and store a malfunction. Therefore, after completing all checks and repairs, the DTC memory must be checked and, if necessary, erased.
Safety precautions See "Multiport Fuel Injection System Safety Precautions". Technician Safety Information
Rules of cleanliness See "Multiport Fuel Injection System Rules For Cleanliness". [1][2]Technician Safety Information
Technical data See "Multiport Fuel Injection System, Technical Data". Specifications
Checking engine operation See "On-Board Diagnostic/Engine Operating Mode, Checking". Testing and Inspection
1 - Air cleaner
2 - Harness connector
- 4-pin
- For Mass Air Flow (MAF) sensor G70
3 - Vacuum pipe
- To EGR vacuum regulator solenoid valve N18
4 - Junction piece
5 - To EVAP canister purge regulator valve N80*/**
- Activated charcoal filter system
6 - Intake air duct
7 - Crankcase breather pressure regulating valve
8 - Intake manifold, upper
- First attach and tighten to lower intake manifold, then to both rear supports -23-
- Disassembling and assembling See "Upper Intake Manifold, Disassembling and Assembling".
9 - 30 Nm (22 ft lb)
- EGR system
10 - Connecting hose
11 - Silencer
- For idle air control valve
12 - To air conditioner
13 - Harness connector
- Only disconnect or connect with ignition switched off
14 - Mounting plate
- For Motronic ECM J220
15 - 10 Nm (7 ft lb)
16 - Motronic Engine Control Module ECM J220*
- Location: in plenum chamber, right
- For fuel injection system, Oxygen Sensor (O2S) control, EVAP canister purge regulator valve, speed governing via fuel pump relay, idle air control, ignition and On Board Diagnostic (OBD)
- Check ECM coding See "On-Board Diagnostic/Coding and Checking Engine Control Module". Testing and Inspection
17 - To vacuum brake booster
18 - Retaining clip
- Check that it is seated securely
19 - O-ring
- Replace if damaged
20 - Engine Coolant Temperature (ECT) sensor -G62-*
- Color: black
- With ECT sensor G2 for gauge
- For Motronic
- Checking See "Engine Coolant Temperature Sensor, Checking".
- Carefully relieve cooling system pressure before removing
21 - Harness connector
- 4-pin
- Terminals 1 and 3 for ECT sensor G62
22 - 20 Nm (15 ft lb)
23 - Support
- Between upper intake manifold and cylinder head
- Tighten only after tightening upper intake manifold to lower
intake manifold
24 - Gasket
- Always replace
25 - Intake manifold, lower
- Disassembling and assembling See "Lower Intake Manifold, Disassembling and Assembling".
26 - Fuel supply hose
- White arrow
- Secure with spring-type clips
- From fuel pump module in fuel tank
27 - Return hose
- Blue arrow
- Secure with spring-type clips
- To fuel tank
28 - Engine Speed (RPM) sensor -G28-*
29 - Spacer
30 - To cylinder block
31 - Deflector
32 - Hose
- To warm air collection plate on exhaust manifold
33 - Heated Oxygen Sensor (HO2S) -G39-*
- Tightening torque: 50 Nm (37 ft lb)
- Location: Three Way Catalytic Converter (TWC)
- Only lubricate threads with "G5"
- Lubricant must not get into slots on probe body
- Check heating voltage supply via Heated Oxygen Sensor (HO2S) relay J278
- Checking HO2S and oxygen sensor control See "Heated Oxygen Sensor and Oxygen Sensor Control, Checking". Testing and Inspection
- Checking oxygen sensor heating See "Oxygen Sensor Heating, Checking". Testing and Inspection
34 - Harness connector
- 4-pin
- For HO2S probe and heating circuit
- Mounted to rear engine mount on right, in direction of travel
35 - Retaining ring