Hyyall. I'm doing up a new 'at a glance' cheatsheet for all the usual engine related problems, diagnostic test(s), expected resulting values, associated error codes (where applicable) and suggested fixes in order of 'most likely' first to 'least likely' last and the associated tech section and/or service manual reference page(s) for more info. Things like misfiring, safety boost, overheating etc etc. Obviously this will go into the tech section when complete. For now, am asking for feedback from personal experience(s) rather than what you may have read somewhere. Trying to keep the format as user/newbie-friendly as possible and relevant to the most common type of problems. Please also note, this is targetted at fixing technical problems rather than 'ricer' / performance modifications. :zlove: Caveats: Can't guarantee all submissions will be added to the final list. Disputes / arguments will undoubtedly arise and will have to be moderated as usual. Lets keep it in the spirit of helping others and not get personal. Remember, don't want to turn this into a 'cast of thousands' production so please lets not get caught up in formatting/layout/grammatical nit-picking and keep the contributions positive. Please reply here (instead of PMs). Here's an example of the format below. Part Coolant Temp Sensor Diagnostic Code 13 Expected results Using a multimeter: Actual Temp = Desired - 20 (68) = 2.1 -2.9 Ohm - 50 (122) = 0.68 - 1.00 Ohm - *80 (176) = 0.30 - 0.33 Ohm - (*Normal Operating Temp) Symptoms -Over-rich mixture - Fouled plugs - Backfire - No start - Auxilary Fan constantly on - Safety boost Fixes - Clean / Replace Dirty/Corroded terminals - Internal fault (Replace) - Wiring Loom- Check continuity to Pin 28 & 30 on ECU - Service Manual EF&EC Page x
PTU ERROR/DIAGNOSTICS Ok, lets get the ball rolling... With this particular problem, I ended up fixing it easily due to a cracked wire that was joining one of the pins of the PTU connector (ecu side). I found this by doing a continuity test in the wiring between there and the ECU connector and was an easy fix in my case. But read through the following checklist if you have similar symptoms as listed below..... Part PTU Diagnostic Code 21 (Ignition Signal Circuit) This error mainly only occurs if there is either a failed PTU (Power Transistor Unit) and/or signal to it from the ECU (ie, wiring harness, connectors between ECU & PTU). Symptoms - In most earlier signs of a failing PTU, engine can run rough (like on 4 or 5 cylinders), and usually occurs when engine is hot, more so than when cold. - In more serious cases, when turning ignition on (not cranking yet), auxillary fan may start up straight away (not normal). Then when cranking, may either not start, or if it does you might need to put accellerator to the floor and (if) it starts then runs rough/stalls. (This means the ECU is in "Failsafe Mode") ..... all these symptoms can be related to a malfunctioning PTU. Fixes - Clean / Replace Dirty/Corroded terminals - Wiring Loom- Check continuity from PTU connector (ECU side) to the actual ECU connector (located in passenger footwell) - Test PTU functionality with multimeter as per this TECH ARTICLE (service manual EF&EC Page 179) - then if internal fault with PTU (Replace, preferrably with a series 2 PTU) Hope this helps. Cheers, Benny_C :zlove:
Alot of the service manual is already in this cheat sheet format. i.e. Measure resistance of xxx, if result is this then good else go to step 2 etc. Or is this something a little different?
Original Conzult manual had a lot of this stuff. Code 11* Camshaft Angle Sensor circuit (CAS) Either 1° or 120° signal is not entered for the first few seconds of engine cranking. Either 1° or 120° signal is not input often enough while the engine speed is higher then the specified RPM. check harness and connector to CAS check CAS (may require replacing) Code 12 Air-Flow Meter circuit (AFM) : Mass Air-Flow Sensor circuit (MAF) The AFM sensor circuit is open or shorted (abnormally high or low voltage is registered). check harness and connector to AFM check AFM (may require replacing) Code 13 Engine Coolant Temperature Sensor The Engine Coolant Temperature Sensor circuit is open or shorted (abnormally high or low voltage is registered). check harness and connector to Engine Temperature sensor check Engine Temperature sensor (may require replacing) Code 14 Speed Sensor circuit The Speed Sensor circuit is open or shorted. check harness and connector to Speed Sensor switch (reed switch) check Speed Sensor switch (may require replacing) Code 21* Ignition signal circuit The ignition signal in the primary circuit is not entered during engine cranking or running. check harness and connector to the Power Transistor Unit check Power Transistor Unit (may require replacing) Code 26 (TT only) Boost Pressure sensor (Turbo models) The boost pressure sensor is open or shorted (abnormally high or low voltage is registered). check harness and connector check for boost pressure leaks check boost pressure sensor (may require replacing) Code 31 ECU - Control Unit ECU calculation function is failing check ECU (may require replacing) Code 32 EGR function EGR valve does not operate (valve spring does not lift) check EGR valve (may require replacing) check EGR solenoid (may require replacing) Code 33 O2 Sensor (left side) The O2 Sensor is open or shorted (abnormally high or low voltage is registered). check harness and connector check O2 sensor (may require replacing) check fuel pressure check injectors (may require replacing) check intake air leaks Code 34 Detonation Sensor circuit The detonation sensor circuit is open or shorted (abnormally high or low voltage is registered). check Harness and connector to Detonation Sensor check Detonation Sensor (may require replacing) Code 35 EGR Temp. Sensor The EGR Temp. Sensor circuit is open or shorted (abnormally high or low voltage is registered). check harness and connector check EGR temperature sensor (may require replacing) Code 42 Fuel Temperature Sensor circuit The Fuel Temperature Sensor circuit is open or shorted (abnormally high or low voltage is registered). check harness and connector check Fuel Temperature Sensor (may require replacing) Code 43 Throttle Position Sensor circuit The Throttle Position Sensor circuit is open or shorted (abnormally high or low voltage is registered). check harness and connector check Throttle Position Sensor (may require replacing) Code 45 Injector leak Fuel leaks from the injectors check Injectors (may require replacing) Code 51 Injector circuit The injector circuit is open check harness and connector check injectors (may require replacing) Code 53 O2 Sensor (right side) The O2 Sensor is open or shorted (abnormally high or low voltage is registered). check harness and connector check O2 sensor (may require replacing) check fuel pressure check injectors (may require replacing) check intake air leaks Code 54 (A/T only) Signal circuit from the automatic transmission (A/T) (A/T models only) The A/T communication line is open or shorted check harness and connector Code 55 No Faults 10. ENGINE ECU MONITOR ? EXPECTED RESULTS NOTE: when there is a left and right item being tested, do not expect them to have exactly the same values or to move in unison. This is because the engine can real be considered as two separate engines (a left bank and a right-bank). Though remember that the left turbo sends air to the right cylinder bank and right turbo sends air to the left cylinder bank. AIR COND SIG Run engine A/C switch `ON' : ON A/C switch `OFF' : OFF -------------------- BATTERY VOLT Ignition on Engine stopped : 11 - 14 volt Engine running : 12 - 15 volt -------------------- CLSD THL/POS Ignition on Throttle position at idle : ON Throttle position slightly open : OFF -------------------- CMPS-RPM(POS) + CMPS-RPM(REF) Connect tachometer Run engine compare tachometer with the ConZult value almost the same value as the ConZult value -------------------- COOLANT TEMP/S Warm up engine More then 70C or 158F -------------------- EGR TEMP SEN Warm up engine Air-Conditioning off Neutral gear no load Less then 4.5 volt -------------------- FUEL TEMP SEN Warm up engine 20 - 60C or 68 - 140F -------------------- IACV-AAC/V Warm up engine Air-Conditioning off Neutral gear no load Idle : 15 - 40 % (Non Turbo) 15 - 35 % (Twin Turbo) 2000rpm : N.A. -------------------- IGN TIMING Warm up engine Air-Conditioning off Neutral gear no load Idle : 15 BTDC 2000rpm : more then 25 BTDC -------------------- INJ PULSE-L & INJ PULSE-R Warm up engine Air-Conditioning off Neutral gear no load Idle : 2.00 - 3.00 msec (Non Turbo) 1.80 - 2.50 msec (Twin Turbo) 2000rpm : 2.00 - 3.00 msec (Non Turbo) 1.80 - 2.20 msec (Twin Turbo) -------------------- MAS AIR/FL SE (Air Flow Meter) Warm up engine Air-Conditioning off Neutral gear no load Idle : 0.80 - 1.50 volt (Non Turbo), 0.90 - 1.40 volt (Twin Turbo) 2000rpm : 1.40 - 1.80 volt (Non Turbo), 1.40 - 1.80 volt (Twin Turbo) -------------------- M/R F/C MNT-L & M/R F/C MNT-R Warm up engine Maintain engine speed at 2000 RPM LEAN <<>> RICH -------------------- O2 SENS-LEFT & O2 SENS-RIGHT Warm up engine Maintain engine speed at 2000 RPM 0.0 - 0.30 <<>> 0.60 - 1.00 volt Note: With no load at 2000rpm in neutral the value should cycle from lean to rich approximately 5 times in ten seconds (at a random interval). On a warm car (80? C), the O2 sensor should move around when the throttle is ?blipped?, if the value remains latched then the O2 sensor has lost sensitivity. If the voltage is fixed in the range of 0.30 to 0.33 then the O2 sensor has lost all sensitivity and it should be replaced. This value is the same as received by the ECU if the sensor was disconnected at the wiring loom plug. -------------------- P/N POSI SW Ignition on Shift lever in P or Neutral : ON Shift lever in any other position : OFF -------------------- PW/ST SIGNAL Run engine Steering wheel in neutral position : OFF Steering wheel is turned : ON -------------------- START SIGNAL Start engine (ignition on start) OFF ON -------------------- THRTL POS SEN Ignition on (engine stopped) Throttle valve fully closed (Idle) : 0.40 - 0.50 volt Throttle valve fully opened: ~ 4.00 volt Note: if went the TPS is adjusted to correct level results in an increase in idle Revs then you will need to adjust the AAC/V adjust down. -------------------- VHCL SPEED SE Drive car compare speedometer with the ConZult value almost the same value as the ConZult value --------------------
Woow Cool, I hadn't seen this before Thank you. No sense reinventing the wheel. but lets keep this thread going as a compilation of people's experiences. cheerz
Eek, I know there's a conZult software user manual on the "ZedStuff" CD, but didn't notice that detailed Quick Reference guide on there... Maybe i missed it
Cheat Sheet was not include but info in Manual For version 2.0 of the Conzult manual the Error Codes are in section "6.2 Work Support ... Diagnostic Trouble Codes ? Error Codes" In Version 1.2 of the Conzult manual the Expected Results are in section "9. ENGINE ECU MONITOR ? EXPECTED RESULTS" The two page cheat sheet was not included by Eric, but I have it as a 2 page PDF and Word doc.
