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Diagnostic Manual, Engines, Volume 2

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2.1 Gasoline Injection System > 23 Electrical Test Program - Test

Electrical Test Program - Test

Test Step	Test scope	Test connection			Test condition	Nominal value	Possible cause/Remedy
1.0 1)	Ground, engine (W11) (connection point for ground wires) Model 124 Model 129	N3 19 N3 19		cir. 30 X4/10 cir. 30	- -	11 - 14 V 11 - 14 V	Wiring, Ground connection W11 (Figure 21) loose. Wiring, Ground connection W11 (Figure 21) loose.
1.1	Ground, battery (W10) Model 124 Ground, component compartment (W16) Model 129	N3 6 N3 6		cir. 30 X4/10 cir. 30	- -	11 - 14 V 11 - 14 V	Wiring, Ground connection W10 (Figure 20) loose. Wiring, Ground connection W16 (Figure 23) loose.
2.0 1)	CFI control module (N3) Voltage supply, Circuit 30a	19	N3	1	-	11 - 14 V	Wiring, Overvoltage protection relay module (K1/1) fuse, K1/1.
2.1	Wiring from N3 to K1/1	N3 1		K1/1 4	CFI control module (N3) unplugged.	< 1	Wiring.
2.2	Wiring from circuit 30 to K1/1	N3 6		K1/1 1	-	11 - 14 V	Wiring.
2.3	Wiring from circuit 30 to K1/1	X4/10 cir. 30		K1/1 1	-	< 1	Wiring.
3.0 1)	CFI control module (N3) Voltage supply, Circuit 87E	19	N3	41	Ignition: ON Overvoltage protection relay module (K1/1) plugged in.	11 - 14 V	Wiring, Connected components are shorted to circuit 31 (ground).

1) On-off ratio 100% when measured with on-off ratio tester.

4.0 Engine systems control module (N16)
Ground
N16

4

X4/10
cir. 30
- 11 - 14 V Wiring,
Loose ground connection:
Model 124: W10 (Figure 20)
Model 129: W16 (Figure 23).

5.0 Engine systems control module (N16)
Voltage supply
Circuit 30

4

N16

1
- 11 - 14 V Wiring,
Loose wire at terminal block, terminal 30/61 (battery) (X4/10):
Model 124: (Figure 25)
Model 129: (Figure 26)

6.0 Engine systems control module (N16)
Voltage supply
Circuit 15 unfused

4

N16

10
Ignition: ON 11 - 14 V Wiring,
Loose wire at fuse and relay box (F1), plug connection:
Model 124: Interior/engine connector (X26) (Figure 30)
Model 129: Multi-function connector block (X30/1) (Figure 31).

7.0 Engine systems control module (N16)
Voltage supply
Circuit 15

4

N16

21
Ignition: ON 11 - 14 V Wiring,
Loose wire at fuse and relay box (F1), plug connection:
Model 124: Interior/engine connector (X26) (Figure 30)
Model 129: Multi-function connector block (X30/1) (Figure 31).

8.0 Fuel pumps (M3m1, M3m2)
Operation

4

N16

21
Ignition: OFF
Engine systems control module (N16) unplugged.

Ignition: ON 11 - 14 V Wiring,
FP harness connector (X36):
Model 124: (Figure 32)
Model 129: (Figure 33)
M3m1 or M3m2.

9.0 Fuel pumps (M3m1, M3m2)
Control

4

N16

2
N16 plugged in.
Connector 2 of DI control module unplugged
(Figure 7).
Engine: Crank
10 ± 2V
while cranking 9.1 ,
N16.

9.1 Control signal,
Circuit 50

4

N16

12
Connector 2 of DI control module unplugged
(Figure 7).
Engine: Crank
10 ± 2V
while cranking Wiring,
Model 124: Interior/engine connector (X26) (Figure 30) defective,
Model 129: AT/engine connector(X22/2) (Figure 29) defective.

10.0 1) Electrohydraulic
actuator (Y1)
Current check

1

Y1

2
Connect test cable
102 589 04 63 00 to Y1.

Ignition: ON Engine 104:
20 mA

Engine 119:
75 mA
Wiring to CFI control module (N3),
Y1.

11.0 1) Electrohydraulic
actuator (Y1)
Malfunction circuit

55

N3

37

Ignition: OFF
Unplug N3 19.5 ± 1 Wiring,
Y1.

11.1 Resistance

1

Y1

2
Ignition: OFF
Y1 unplugged
19.5 ± 1 Y1.

11.2 Wiring

N3
37
55

Y1
1

2

Ignition: OFF
N3 and Y1 unplugged. < 1 Wiring,
Wires in connector (Y1) reversed.

1) On-off ratio 90% when measured with on-off ratio tester.

12.0 1) 2) WOT/CTP switch (S29/2)
Malfunction circuit -
WOT contact

19

N3

46
Ignition: OFF
Unplug CFI control module (N3) connector and connec-tor "B" (Figure 7) of DI control module (N1/3).
Ignition: ON (ASR only)

Accelerator pedal in CTP

Disconnect AT control pressure cable on vehicles without ASR.

Accelerator pedal in WOT position.

< 1
Wiring,
WOT contact,
S29/2,
Polarity reversed at connector S29/2x1:
Engine 104: (Figure 18),
Engine 119: (Figure 19).

12.1 WOT contact

2

S29/2x1

3
Ignition: ON (ASR only)
Connector (S29/2x1) unplugged:
Engine 104: (Figure 18)
Engine 119: (Figure 19)

Accelerator pedal in CTP

Accelerator pedal in WOT position.

< 1

Adjust or replace S29/2.

1) On-off ratio 20% when measured with on-off ratio tester.
2) On-off ratio 10% when measured with on-off ratio tester.

12.2 Wiring
N3
46

S29/2x1
3
Ignition: OFF
CFI control module (N3) unplugged.
< 1 Wiring.

12.3 Wiring
W11

S29/2x1
2
Ignition: OFF < 1 Wiring,
Ground connection (W11) loose (Figure 21).

13.0

1) ECT sensor (B11/2)
Malfunction circuit

35

N3

16
Ignition: ON See Table I Wiring,
B11/2,
CFI control module (N3).

13.1 B11/2

1

2

B11/2

B11/2

3

4

B11/2 connector unplugged.
Measure connections diagonally and compare both values (Figure 12). See Table I
(both values must be the same). B11/2.

13.2 Wiring
N3
16
35

B11/2
2

4
Ignition: OFF
N3 connector unplugged.
Terminal layout of connector (B11/2,
Figure 12).
< 1 Wiring.

1) On-off ratio 30% when measured with on-off ratio tester.

14.0 1) 2) VAF sensor (B2)
Malfunction circuit

34

34

N3

N3

31

52

Engine: at Idle
and at operating temperature.

4.6 -5.1 V

0. 55 - 0.95 V B2,
CFI control module (N3),

Wiring,
N3
B2.

14.1 B2

1

B2

3
Ignition: OFF
Connector on B2 unplugged. 3.6 - 4.4 k B2.

14.2 B2

1

B2

2
Slowly deflect air flow sensor plate by hand. -value increases continuously up to 2/3 of travel, then decreases again. B2.

14.3 Wiring
N3

34

52

31

B2
1

2

3
Ignition: OFF
N3 connector unplugged. < 1 Wiring.

1) On-off ratio 40% when measured with on-off ratio tester.
2) On-off ratio 10% when measured with on-off ratio tester.

15.0 1) TN-signal

19

N3

27
Engine: at Idle 5 - 7 V Wiring,
16.2 ,
TN-signal implausible,
other connected components defective.

15.1 Wiring

N3

27

N16

11

Ignition: OFF < 1 Wiring.

16.0 TN-signal

4

N16

16

Engine: at Idle 5 - 7 V Wiring,
DI control module (N1/3).

16.1 TN-signal wire

N1/3
4
(A)

N16

16
Ignition: OFF
Connector (A) of N1/3 unplugged (Figure 7). < 1 Wiring.

16.2 Engine systems control module (N16)

4

N16

11
Ignition: OFF
Connector (A) of N1/3 connected.
Engine: at Idle
5 - 7 V N16.

1) On-off ratio 70% when measured with on-off ratio tester.

17.0 1) WOT/CTP switch (S29/2)
Malfunction circuit -
CTP contact

19

N3

47
Ignition: OFF
CFI control module (N3) unplugged.

Accelerator pedal in CTP

Depress accelerator pedal

< 1

Wiring,
CTP contact.

17.1 CTP contact

1

S29/2x1

2
Ignition: OFF
Connector (S29/2x1) unplugged.
Engine 104: (Figure 18)
Engine 119: (Figure 19)

Accelerator pedal in CTP

Accelerator pedal in WOT position

< 1

Adjust or replace S29/2.

17.2 Wiring
N3

47

S29/2x1
1

Ignition: OFF
N3 unplugged. < 1 Wiring.

1) On-off ratio 10% when measured with on-off ratio tester.

17.3 Wiring

W11

S29/2x1
2
Ignition: OFF
Connector (S29/2x1) unplugged. < 1 Wiring,
Ground connection (W11) loose (Figure 21).

18.0 1) Vehicle speed signal

19

N3

29
Ignition: OFF
ASR control module (N30/1) connector unplugged.

Engine: Start
Drive vehicle onto chassis dynamometer, "drive" vehicle at > 20 km/h
(> 13 mph).

Model 124:
Ignition: ON
Roll vehicle approx. 1 meter. < 1 V

Needle oscil-lates: 0 - 12 V
(0 - 9 V with consumers)
Wiring,
Model 124: Hall-effect speed sensor (B6),
Model 129: Electronic speedometer (A1p8).

18.1 Wiring
Model 124
N3

19

X53/5

Ignition: OFF
CFI control module (N3) and Hall-effect sensor multipoint connector (X53/5) unplugged.
< 1 Wiring,
Hall-effect speed sensor (B6).

1) On-off ratio 60% when measured with on-off ratio tester.

[18.1] Model 129
N3
29

X30/1
3
(A2)
Ignition: OFF
CFI control module (N3) and connector A2 of multi-function connector block (X30/1) (Figure 31) unplugged.
< 1 Wiring,
Check X30/1 (Figure 31).

18.2 Wiring
Model 129
X30/1
3
(A2)

A1p8
1
(1)
Ignition: OFF
Connector (1) of A1p8 unplugged.
< 1 Wiring,
Check A1p8, see DM, body and accessories, Vol. 1 - 1.2.

19.0 1) Data line
CFI control module (N3)
DI control module (N1/3)
N3
26

N1/3
7
(A)

Ignition: OFF
Connector (A) of N1/3 unplugged (Figure 7). < 1 Wiring,
Check for correct part no. matching of control modules N3 and N1/3.

20.0
IAT sensor (B17/2)
Malfunction circuit

5

N3

14
Ignition: ON See Table I Wiring,
Engine 104: (Figure 1),
Engine 119: (Figure 2),
B17/2,
N3.

1) On-off ratio 80% when measured with on-off ratio tester.

20.1 Resistance

2

B17/2

3
Ignition: OFF
Connector of B17/2 unplugged.
See Table I B17/2.

20.2 Wiring
N3
5

14

B17/2
2

3

Ignition: OFF
CFI control module (N3) and B17/2 unplugged. < 1 Wiring.

21.0 1) O2S 1 (beforeTWC) (G3/2)
Malfunction circuit

19

N3

13
Engine: at Idle
and at operating temperature.
Oscillates between
0.1 - 0.9 V Wiring,
G3/2,
N3,
35.0
Check mixture adjustment.

21.1 Insulation,
O2S 1 wire

32

N3

13
Ignition: OFF
N3 connector and O2S 1 signal connector (G3/2x2) orO2S 1 connector (G3/2x1) unplugged.
Model 124: (Figure 13)
Model 129: (Figure 14).
Wiring.

1) On-off ratio 50% when measured with on-off ratio tester.

21.2 O2S 1 wire 1)
Model 124

Model 129
N3

13

N3

13

G3/2x2

G3/2x1
3
Ignition: OFF
CFI control module (N3) and O2S 1 signal connector (G3/2x2) unplugged.

Ignition: OFF
CFI control module (N3) and O2S 1 connector (G3/2x1) unplugged.
< 1

< 1 Wiring,

Wiring.

21.3 O2S 1 (before TWC) (G3/2)
N3

13

2 V
On-off ratio tester connected.
Engine: at Idle
Connector G3/2x1 connected.
0 - 10% at on-off ratio tester after 30 seconds. G3/2.

21.4 CFI control module (N3)

13

N3

6
On-off ratio tester connected.
Engine: at Idle
Connector G3/2x1 unplugged. 90 - 100% at on-off ratio tester after 30 seconds. N3.

22.0 O2S 1 heater
Voltage supply

4

N16

20
Engine: at Idle 11 - 14 V Wiring,
N3,
Engine systems control
module (N16).

1) Drive vehicle onto lift.

22.1 Control signal
O2S 1 heater

4

N16

18

Engine: at Idle 11 - 14 V Wiring,
CFI control module (N3).

22.2 Wiring
N3

3

N16

18
Ignition: OFF
N3 and engine systems control module (N16) unplugged.
< 1 Wiring.

22.3 Control signal
O2S 1 heater

20

N16

1
Ignition: OFF
N16 unplugged.
O2S 1 connector (G3/2x1) connected.
Model 124: (Figure 13)
Model 129: (Figure 14).
0.5 - 1.7 A Wiring,
O2S 1 (before TWC) (G3/2).

22.4 Model 124
Wiring

G3/2x1
2

N16

20

Ignition: OFF
N16 and G3/2x1 unplugged.
< 1 Wiring.

[22.4] Model 129
Wiring 1)

G3/2x1
2

N16

20

N16 and G3/2x1 unplugged. < 1 Wiring.

22.5 Model 124
Wiring

Model 129
Wiring 1)
G3/2x1
1

G3/2x1
1

W10

W16

Ignition: OFF
O2S 1 heater coil connector (G3/2x1) unplugged.

Ignition: OFF
Connector G3/2x1 unplugged.
< 1

< 1 Wiring,

Wiring.

23.0 Adjustable camshaft timing solenoid (Y49) and mechanical camshaft adjustment
Engine 104
N3

1

N3

6

Y49
2

Y49
1
Ignition: OFF
Connector on Y49 unplugged.
Engine: at Idle

Bridge for a max. of 10 seconds.

Engine shakes Y49,
Check mechanical camshaft adjustment (see SMS, Repair Instructions, Engine 104, Group 05, Job No. 217).

1) Drive vehicle onto lift.

24.0 Engine 104
Camshaft adjustment (electrical) (Y49)

1

Y49

2
Ignition: OFF
Connect test cable
102 589 04 63 00 to adjustable camshaft timing solenoid (Y49).
Engine: Start

Increase engine speed to approx. 2000 rpm.
Briefly 1.5 A,
then 1 A Wiring,
Y49,
CFI control module (N3).

25.0 Engine 119
Left adjustable camshaft timing solenoid (Y49/1) and left mechanical camshaft timing adjustment
N3

1

N3

6

Y49/1
2

Y49/1
1

Ignition: OFF
Connector on Y49/1 unplugged.
Engine: at Idle

Bridge for a max. of 10 seconds.

Engine shakes Y49/1,
Check mechanical camshaft adjustment (see SMS, Repair Instructions, Engine 119, Group 05, Job No. 217).

26.0 Engine 119
Left camshaft adjustment (electrical) (Y49/1)

1

Y49/1

2
Ignition: OFF
Connect test cable
102 589 04 63 00 to adjustable camshaft timing solenoid (Y49/1).
Engine: Start

Increase engine speed to approx. 3000 rpm.
Briefly 1.5 A,
then 1 A Wiring,
Y49/1,
Chech contacts at engine separation point connector (X26/2),
CFI control module (N3).

26.1 Left camshaft adjustment
Control

40

N3

41
Increase engine speed to approx. 3000 rpm. Briefly 7.5 V
then approx. 5 V If nominal value is greater than
11 V, check CFI control module (N3) wiring for open circuit,
26.2.

26.2 Left adjustable camshaft timing solenoid (Y49/1)

1

Y49/1

2
Ignition: OFF
Connector on Y49/1 unplugged.
5 ± 1 Y49/1.

26.3 Wiring
N3
41

40

Y49/1
2

1

Ignition: OFF
CFI control module (N3) and connector on Y49/1 unplugged.
< 1 Wiring

27.0 Engine 119
Right adjustable camshaft timing solenoid (Y49/2) and right mechanical camshaft adjustment
N3
1

N3
6

Y49/2
2

Y49/2
1

Ignition: OFF
Connector on Y49/2 unplugged.
Engine: at Idle

Bridge for a max. of 10 seconds.

Engine shakes Y49/2,
Check mechanical camshaft adjustment (see SMS, Repair Instructions, Engine 119, Group 05, Job No. 217).

28.0 Right camshaft adjustment (electrical) (Y49/2)

1

Y49/2

2
Ignition: OFF
Connect test cable
102 589 04 63 00 to adjustable camshaft timing solenoid (Y49/2).
Engine: Start

Increase engine speed to approx. 3000 rpm.
Briefly 1.5 A,
then 1 A
Wiring,
Y49/2,
CFI control module (N3).

28.1 Right camshaft adjustment
Control

22

N3

41

Increase engine speed to approx. 3000 rpm. Briefly 7.5 V
then approx. 5 V Wiring,
Y49/2,
N3.

28.2 Right adjustable camshaft timing solenoid (Y49/2)

1

Y49/2

2
Ignition: OFF
Connector on Y49/2 unplugged.
5 ± 1 Y49/2.

28.3 Wiring
N3
41

22

Y49/2
2

1
Ignition: OFF
CFI control module (N3) and connector on Y49/2 unplugged.
< 1 Wiring.

29.0 A/C compressor engagement signal

6

N3

45
Engine: at Idle
Switch ON automatic climate control (A/C compressor). 5 - 10 V Wiring,
Engine systems control
module (N16),
Check A/C compressor cut-out (see DM, Climate Control, Vol. 1).

29.1 Wiring
N16

9

N3
45
Ignition: OFF
N3 and A/C compressor control module (N6) unplugged.
< 1 Wiring.

30.0 Electromagnetic AIR pump clutch (Y33)
Control

4

N16

19
Ignition: OFF
ECT sensor (B11/2) unplugged. Using two resistance substitution units, simulate 2.5 k resistance (+ 20°C) at sockets 2 and 4 as well as at sockets 1 and 3
(Figure 12).

Engine: at Idle

Disconnect air hose to check valve.
11 - 14 V
(for approx. 2 minutes after start)

Noticeable air flow at air hose. 30.1 ,
Engine systems control
module (N16).

30.1 Secondary air injection control signal

17

N16

21
Ignition: OFF
ECT sensor (B11/2) unplugged. Simulate 2.5 k resistance (+ 20°C) at sockets 2 and 4 as well as at sockets 1 and 3
(Figure 12).
Engine: at Idle
11 - 14 V
(for approx. 2 minutes after start) Wiring,
CFI control module (N3).

30.2 Wiring
N3
42

N16
17

Ignition: OFF
N3 and N16 unplugged. < 1 Wiring.

30.3 AIR pump switchover
valve (Y32)
Control

1

Y32

2
Ignition: OFF
ECT sensor (B11/2) unplugged. Simulate 2.5 k resistance (+ 20°C) at sockets 2 and 4 as well as at sockets 1 and 3
(Figure 12).
Connector on Y32 unplugged.
Engine: at Idle
11 - 14 V
(for approx. 2 minutes after start) Wiring to Y32 (located in engine compartment):
Model 124: (Figure 5),
Model 129: (Figure 6).

30.4 AIR pump switchover
valve (Y32)

1

Y32

2
Ignition: OFF
Connector on Y32 unplugged.
25 ± 5 Y32.

30.5 Electromagnetic AIR pump clutch (Y33)
Control

1

Y33

2
Ignition: OFF
ECT sensor (B11/2) unplugged. Simulate 2.5 k resistance (+ 20°C) at sockets 2 and 4 as well as at sockets 1 and 3
(Figure 12).
Connector on Y33 unplugged.
Engine: at Idle
11 - 14 V
(for approx. 2 minutes after start) Wiring to Y33 (located in harness channel in front of right spring tower).

30.6 Electromagnetic AIR pump clutch (Y33)

1

Y33

2
Connector on Y32 unplugged.
5 ± 1 Y33.

31.0 Start valve (Y8)
Control

20

N3

41
Ignition: OFF
ECT sensor (B11/2) unplugged. Using two resistance substitution units, simulate 2.5 k resistance (+ 20°C) at sockets 2 and 4 as well as at sockets 1 and 3
(Figure 12).
Engine: at Idle
Briefly
10 ± 2 V CFI control module (N3), see "Testing Starting System" ( 33 ),
32.0.

32.0 Start valve (Y8)
Resistance

1

Y8

2
Ignition: OFF
Connector on Y8 unplugged.
10 - 15 Y8.

32.1 Wiring
N3

20
41

Y8
1

2

Ignition: OFF < 1 Wiring,
Intermittent contact (X26/2).

33.0 ISC valve (Y6)
Current check

1

Y6

2
Ignition: OFF
Connect test cable to Y6.

Engine: at Idle Engine 104
600 ± 50 mA

Engine 119
700 - 1000 mA
Wiring,
Intermittent contact (X26/2),
CFI control module (N3).

33.1 Resistance

1

Y6

2
Ignition: OFF Engine 104
7.5 - 10

Engine 119
3.5 - 5.5
Y6,
Intermittent contact (X26/2).

33.2 Wiring
N3

23
4

Y6
1

2

Ignition: OFF
N3 unplugged. < 1 Wiring,
Intermittent contact (X26/2).

34.0 Charcoal canister purging
Operation

Note to Test connection:
Connect vacuum tester to side connection (B) of purge valve (53):
Model 124: (Figure 8),
Model 129: (Figure 9, 11).

Ignition: OFF
Purge line (B, Figures 8, 9 or 11) disconnected from charcoal canister at purge valve.
Engine: at Idle and at operating temperature. Slowly increase engine speed to a maximum of 3000 rpm.
Vacuum increases with increasing rpm. Wiring,
CFI control module (N3),
Purge control valve (Y58/1),
Check vacuum lines,
13.0 ,
Intermittent contact (X26/2).

34.1 Purge control valve (Y58/1)
Control

2

N3

41
Engine: at Idle
Increase engine speed to
> 800 rpm 11 - 14 V Wiring,
N3,
Y58/1,
Intermittent contact (X26/2).

34.2 Purge control valve (Y58/1)

1

Y58/1

2
Ignition: OFF
Connector on Y58/1 (Figures 8, 10) unplugged.
25 ± 5 Y58/1.

34.3 Wiring
N3

2

41

Y58/1
1

2

Ignition: OFF
N3 unplugged. < 1 Wiring,
Intermittent contact (X26/2).

35.0 Non-USA vehicles.
Continue to next test step.

36.0 1) Circuit 50
Activation

6

N3

11
Plug 2 on DI control module (N1/3) disconnected
(Figure 7).
Engine: Start
10 ± 2 V while cranking Wiring (circuit 50).

1) On-off ratio 70% when measured with on-off ratio tester.

37.0 Deceleration shut-off
Engine 104

Note to Test connection:
Connect to
diagnostic socket (X11).

Engine: Start
Increase engine speed to 2000 - 2500 rpm, then close throttle valve.
On-off ratio momentarily jumps up to 95%. Wiring,
Check adjustment of linkage and throttle valve switch,
S27/2.

37.1 Deceleration shut-off microswitch (S27/2)

10

N3

6
Ignition: OFF
CFI control module (N3) unplugged.
Accelerator pedal in CTP.

Depress accelerator pedal.

< 1

Open circuit, S27/2.

Short circuit, S27/2.

37.2 Vehicles with ASR
Idle speed switching signal

6

N3

41
Ignition: ON
Accelerator pedal in CTP.

Depress accelerator pedal.

11 - 14 V

< 1 V
ACCelerator pedal position sensor,
Check EA/CC/ISC control module (N4/1), see DM, Engines,
Vol. 2 - 6.1.

37.3 Electrohydraulic actuator (Y1)
Current check

1

Y1

2
Ignition: OFF
Connect test cable
102 589 04 63 00 to electrohydraulic actuator.

Engine: Start
Increase engine speed to 2000 - 2500 rpm and close throttle valve.
Momentarily approx. - 60 mA until combustion resumes. 1.0 - 3.0 and 10.0 ,
N3.

38.0 Engine 104
Kickdown cut-out
Malfunction circuit

Engine 119
Kickdown cut-out
Malfunction circuit

7

N16

1
Ignition: OFF
Engine systems control module (N16) unplugged.
Kickdown switch (S16/6) activated. Engine 104:
450 ± 50 mA 1)
850 ± 50 mA 1)

Engine 119 :
450 ± 50 mA 1)
250 ± 50 mA 1)
Wiring,
S16/6,
AT kickdown valve (Y3, Figure 4).

38.1 Kickdown switch (S16/6)
Voltage supply

7

N16

1
Ignition: OFF
N16 unplugged.

Ignition: ON
Accelerator pedal in CTP.

Accelerator pedal in kickdown position.

< 1 V

11 - 14 V s16/6,
AT kickdown valve (Y3, Figure 4).
Wiring,
38.2.

1) Nominal value may ary from one nanufacturer to annother.

38.2 Kickdown switch (S16/6)
Resistance

2

S16/6

4
Ignition: OFF
Kickdown switch (S16/6) activated.

Kickdown switch (S16/6) not activated.

< 1

S16/6.

38.3 AT kickdown valve (Y3) or kickdown solenoid
valve (Y3/1y1) 2)

W11

Y3 or
Y3/1y1
Ignition: OFF
Connector Y3 unplugged or, with 5-speed AT, valve block connector (Y3/1x1) disconnected.
12± 3 1)
28 ± 5 1) Y3 or Y3/1y1.

1) Nominal value may ary from one nanufacturer to annother.
2) Kickdown solenoid valve (Y3/1y1) in 5-speed AT 722.5 only.

39.0 EGR valve (static test)

Note to Test connection:
Connect vacuum tester to EGR valve.

Apply 500 mbar vacuum.
Disconnect vacuum line on EGR valve.
EGR valve closes audibly EGR valve.

39.1 EGR valve (dynamic test)

Note to Test connection:
Vacuum tester connected to EGR valve.

Engine: at Idle
Engine rpm > 1000 rpm > 400 mbar Vacuum lines,
Vacuum supply,
EGR switchover valve (Y27),
Model 124: (Figure 5),
Model 129: (Figure 6),
Throttle valve housing.

40.0 EGR switchover
valve (Y27)
Control

38

N3

41

Engine: at Idle
Engine rpm > 3000 rpm Approx. 12 V Wiring,
CFI control module (N3).

40.1 EGR switchover valve (Y27)

Y27

Ignition: OFF 30 ± 5 Y27:
Model 124: (Figure 5),
Model 129: (Figure 6).

40.2 Wiring
N3

38

41

Y27
1

2

Ignition: OFF
N3 and Y27 unplugged. < 1 Wiring.

41.0 Non-USA vehicles.
Continue to next test step.

42.0 Non-USA vehicles.
Continue to next test step.

43.0 Non-USA vehicles.
Continue to next test step.

44.0 Transmission upshift delay relay module (K29)
Solenoid valve (Y3/2)
Control
W11

Y3/2

Ignition: OFF
ECT sensor (B11/2) unplugged. Using two resistance substitution units, simulate 2.5 k resistance (+ 20°C) at sockets 2 and 4 as well as at sockets 1 and 3
(Figure 12).
Engine: at Idle
11 - 14 V
Engine 104:
max. 80 sec.

Engine 119:
max. 120 sec. 44.1 ,
44.2 ,
44.3 ,
44.4 ,
CFI control module (N3),
K29.

44.1 Transmission upshift delay relay module (K29)
Voltage supply
W11

W11

K29
3

K29
4

Ignition: OFF
K29 unplugged:
Model 124: (Figure 16),
Model 129: (Figure 17).
Ignition: ON 11 - 14 V

11 - 14 V
Overvoltage protection relay (K1/1),
Wiring.

44.2 Wiring to solenoid valve (Y3/2)

1

W11

K29

4

Y3/2x1

Ignition: OFF
Transmission upshift delay relay (K29) unplugged:
Model 124: Figure 16
Model 129: Figure 17
Solenoid valve connector (Y3/2x1) unplugged.
Ignition: ON 11 - 14 V Open circuit.

44.3 Solenoid valve (Y3/2)

Y3/2

Ignition: OFF
Solenoid valve connector (Y3/2x1) unplugged.
10 - 18 Y3/2.

44.4 Wiring from CFI control module (N3) to transmission upshift delay relay
module (K29)
K29

5

N3

39
Ignition: OFF
Socket box connected
to N3.
K29 unplugged. < 1 Open circuit.

45.0 Transmission upshift delay switchover valve (Y3/3)
Operation

Note to Test connection:
Disconnect vacuum line (Figure 38) on Y3/3.

Connect vacuum tester with Y-distributor to Y3/3.

Ignition: OFF
ECT sensor (B11/2) unplugged. Using two resistance substitution units, simulate 2.5 k resistance (+ 20°C) at sockets 2 and 4 as well as at sockets 1 and 3
(Figure 12).
Engine: at Idle
> 400 mbar (for a maximum of 80 seconds) Control of Y3/3,
Short/open circuit,
Y3/3 defective,
Vacuum element for transmission upshift delay,
Vacuum line.

45.1 Control
W11

Y3/3
1

Y3/3
2

+

Ignition: OFF
Connector of Y3/3 (Figure 38) unplugged. Using two resistance substitution units, simulate 2.5 k resistance (+ 20°C) at sockets 2 and 4 as well as at sockets 1 and 3
(Figure 12).

Engine: Start
11 - 14 V

11 - 14 V (for a maximum of 80 seconds)
Overvoltage protection relay module (K1/1),
Short/open circuit.

Short/open circuit,
CFI control module (N3).

45.2 Coil resistance
Y3/3
1

Y3/3
2
Ignition: OFF
Connector of Y3/3 (Figure 38) unplugged. 25 - 40 Y3/3 defective.

Temperature (oC) Resistance ( ) Voltage (V) at IAT sensor (B17/2) Voltage (V) at ECT sensor (B11/2)

- 20 15700 2.85 - 3.49 5.12 - 5.60

- 10 10000 2.50 - 3.06 4.49 - 5.11

0 5900 2.10 - 2.56 4.12 - 4.48

10 3700 1.69 - 2.07 3.77 - 4.11

20 2500 1.32 - 1.62 3.36 - 3.76

30 1700 1.03 - 1.25 2.92 - 3.35

40 1170 0.77 - 0.94 2.51 - 2.91

50 830 0.57 - 0.69 2.09 - 2.50

60 600 0.42 - 0.52 1.69 - 2.08

70 435 0.32 - 0.40 1.36 - 1.68

80 325 0.25 - 0.31 1.09 - 1.35

90 245 0.18 - 0.22 0.88 - 1.08

100 185 0.14 - 0.17 0.75 - 0.87