• If there is an engine fault, it is not recognised by the Motronic ECU

- No Signal

• Open circuit or short circuit from pin 50 on J220 to G21 in inst. cluster

• Vehicle speed sensor (G68) malfunctioning

• A/C compressor does not shut off during wide open throttle
• Value briefly drops below idle speed when clutch disengaged during deceleration fuel shut off
• Idle speed limited to 5300 RPM

• Check vehicle speed sensor G68
• Check electrical connections

- No change in signal

- Mechanical fault

• Foreign material on G28
• G28 loosely mounted
• Distance from G28 to ring gear on flywheel exceeds 1.2mm
• Broken teeth on flywheel ring gear
• Open circuit between 3-pin connector in engine bay and G28
• Open circuit between J220 and G28
• Short circuit between terminal 47 and 3-pin connector and J220 shielding or ground
• Open circuit in G28 shielding 

• 3-pin connector from G28 and G4 connected in reverse
• G28 faulted
• J220 faulty

• Engine does not start
• Engine misfires
• Engine stalls

• Engine does not start

• Check Engine Speed Sensor G28
• Repair short or open circuit
• Check electrical connections

• Reverse G4 and G28 harness connectors

- No change in signal

- Mechanical fault

• G4 loosely mounted

• Distance from G4 to pin gear on flywheel exceeds 1.2mm

• Pin on flywheel bent or broken

• Open circuit between 3-pin connector in engine bay and G4

• Open circuit between G4 and J220

• Short circuit between terminal 49 and J220 or shielding and ground

• Open circuit in shielding and G4

• 3-pin connector from G4 and G28 reversed in engine bay

• G4 faulty

• J220 faulty

• Engine does not start

• Check G4

• Repair short or open circuit

• Check electrical connections

- Open or Short circuit to B+

- Signal to B+

- Short to ground

- Signal to ground

- Mechanical fault

• No power supply to G40 from J220

• No ground for G40

• Bad connection from J220 or short circuit to ground

• Short circuit between pin 8 and 12 on J220

• G40 faulty

• J220 faulty

• Camshaft timing belt disengaged

• Pin for G4 bent or broken

• Engine does not start

• Power Loss

• Check G40

• Repair short or open circuit

• Check electrical connections

• Check timing belt

• Check G40

• Check G4 pin

- Open or Short to B+

- Short to ground

- Signal to ground

• F60 out of adjustment

• Throttle body sticking

• Throttle cable in need of adjustment

• Open circuit between F60 and J220

• J220 faulty

• Short circuit between J220 and ground

• Moisture in throttle body connector

• Idle speed erratic or outside specification

• Check & adjust F60

• Check F60 potentiometer and switches

• Adjust throttle cable

• Repair open or short ciruit

• Check electrical connections

• Repair short circuit

- Open or short to B+

- Short to ground

- Signal too high

- Signal too low

- Invalid signal

• Open or short to +ve terminal in G69

• Short to ground in G69 or in wiring loom to J220

• G69 faulty

• J220 faulty

• Damp and/or corrosion in G69 connector

• Engine runs roughly during acceleration

• Check G69

• Check electrical connections

- Signal too low

- Signal too high

- Control difference

• Vacuum line between inlet manifold and J220 pinched, plugged or constricted/bent

• Fluid separator in tube from inlet manifold to J220 full of water

• Wastegate faulty

• Wastegate frequency valve faulty

• MAP sensor in J220 faulty

• Turbocharger faulty

• Loss of power

• Check vacuum tube and fluid separator

• Check wastegate and frequency valve

• Check turbocharger

- Signal to ground

- Signal to B+

• Short to ground

• Moisture in G52 wiring harness

• Open circuit between G62 and J220

• G62 faulty

• J220 faulty

• Cold start problems
• Erratic idle and/or poor acceleration during warm up

• Check G62

- Short to ground

- Open or Short to B+

• Short to ground

• Open circuit between G42 and J220

• G42 faulty

• J220 faulty

• Slight loss of power

• Increased fuel consumption

• Check G42

- No change in signal

• G61 connector loose or corroded

• Open or short between G61 and J220

• Short between G61 and ground or to shielding

• G61 faulty

• J220 faulty

• High fuel consumption

• Loss of power

• Check torque on knock sensor (20Nm)

• Check electrical connections and repair any short or open circuits

- Signal to B+

- Signal to ground

- No change in signal

• Open circuit to J220

• Lambda sensor heater (Z19) faulty

• Fuse for Z19 blown

• G39 faulty

• Signal wire short to ground or shielding

• Ignition system failure

• Intake leak after mass air flow sensor (G70)

• Leak in exhaust system before catalysts

• Ground wire between pin 10 on J220 and engine block open circuit

• Emissions out of specification

• Increased fuel consumption

• Rich exhaust

• Fouled spark-plugs

• CO before catalyst in excess of 3%

• Check electrical connections and repair any short or open circuits

• Check Z19

- Open or short to B+

- Short to ground

•  Short to B+ in F96 or in wiring harness to J220

• Short to ground in F96 or in wiring to J220

• F96 faulty

• J220 faulty

• Loss of power

• Low boost pressures

• Check F96

• Check electrical connections and repair any short or open circuits

• Check boost pressure

- Signal too high

- Signal too low

• Supply voltage (B+) into J220 exceeds 16 volts

• Faulty alternator

• Poor ground at J220

• Flat battery

• Engine does not start and/or crank

• Erratic idle

• Check electrical connections 

• Check voltage supply at battery AND alternator

• Check J220

- Maximum adaptation exceeded

- Mimimum adaptation not reached

• Idle stabiliser (N71) binds when closed

• Mass air flow offset (G70)

• Resistance at N71 out of specification

• Faulty connection into N71

• N71 binds when open

• G70 offset

• Extra air induced between G70 and N71

• Idle speed too low

• Idle speed too high

• Check electrical connections

• Check N71

• Check G70

• Check G19

• Repair air leak

- Maximum control limit exceeded

- Minimum control limit exceeded

• Low fuel pressure (<3.3 bar)

• Ignition system faulty

• Intake air leak after G70

• Leak in exhaust prior to catalyst

• G39 faulty

• Fuel pressure too high (> 4 bar)

• CO before catalyst less than 0.5%

• High fuel consumption

• Rich exhaust

• Fouled spark plugs

• CO before catalyst greater than 3%

•  Check fuel pressure

• Repair air leak

• Check G39

• Check fuel pressure

- No change in signal

• G66 connector loose or corroded

• Open or short between G66 and J220

• Short between G66 and ground or to shielding

• G66 faulty

• J220 faulty

• High fuel consumption

• Loss of power

• Check torque on knock sensor (20Nm)

• Check electrical connections and repair any short or open circuits

-  Signal too high

• Driver has heavy foot

:)

• Keep revs below 7440 RPM

- Incorrect signal

• Intake air leak after turbocharger

• Wastegate frequency valve (N75) faulty

• Vacuum tube from inlet manifold and J220 has leak or is disconnected

• MAP sensor in J220 is faulty

• Misfire during wide open throttle

• Boost pressure too high

• Check hoses and connectors for leaks

• Check boost pressure

• Check N75

- Signal too low

- Signal too high

• Open circuit between G70 and J220

• Voltage supply to G70 interrupted or short to ground

• Pin 7 on J220 shorted to ground

• G70 faulty

• J220 faulty

• Limp home mode

• Poor throttle response

• Poor performance

• Check electrical connections and repair any short or open circuits

• Check G70

- Adaptation limit (mul) exceeded

- Adaptation limit (mul) not reached

Adaptation limit (add) exceeded

- Adaptation limit (add) not reached

• Fuel pressure too low

• Ignition system faulty

• Leakage in exhaust system before catalyst

• Incorrect signal from G70

• Increased fuel consumption

• Sooty exhaust

• Check fuel system & pressure

• Check exhaust system for leakage

• Check G70

- Control limit exceeded

• Poor fuel quality (less than 95 RON)

• Open circuit in signal wire between G28 and G4

• Abnormal engine noise due to loose component(s)

• Open circuit to knock sensor #1 (G61) shielding

• High fuel consumption

• Loss of power & performance

• Low boost pressure

• Fill tank with 95 RON

• Check G28 and G4

• Check G61 and associated wiring

- Control limit exceeded

• Poor fuel quality (less than 95 RON)

• Open circuit in signal wire between G28 and G4

• Abnormal engine noise due to loose component(s)

• Open circuit to knock sensor #1 (G61) shielding

• High fuel consumption

• Loss of power & performance

• Low boost pressure

• Fill tank with 95 RON

• Check G28 and G4

• Check G61 and associated wiring

- Control limit exceeded

• Poor fuel quality (less than 95 RON)

• Open circuit in signal wire between G28 and G4

• Abnormal engine noise due to loose component(s)

• Open circuit to knock sensor #1 (G61) shielding

• High fuel consumption

• Loss of power & performance

• Low boost pressure

• Fill tank with 95 RON

• Check G28 and G4

• Check G61 and associated wiring

- Control limit exceeded

• Poor fuel quality (less than 95 RON)

• Open circuit in signal wire between G28 and G4

• Abnormal engine noise due to loose component(s)

• Open circuit to knock sensor #2 (G66) shielding

• High fuel consumption

• Loss of power & performance

• Low boost pressure

• Fill tank with 95 RON

• Check G28 and G4

• Check G66 and associated wiring

- Control limit exceeded

• Poor fuel quality (less than 95 RON)

• Open circuit in signal wire between G28 and G4

• Abnormal engine noise due to loose component(s)

• Open circuit to knock sensor #2 (G62) shielding

• High fuel consumption

• Loss of power & performance

• Low boost pressure

• Fill tank with 95 RON

• Check G28 and G4

• Check G66 and associated wiring

- Signal to B+

- Signal to ground

• Short to B+ in N80 or between N80 and pin 5 on J220

• Short to ground in N80 or between N80 and pin 5 on J220

• Fuse blown

• Open circuit

• Poor response in portion of load range

• Possible fuel odour

• Check N80 and associated wiring

• Check fuse

- Signal to ground

- Signal to B+

• Short to ground

• Open circuit or faulty connector

• Short to B+ at connector or injector

• Fuse blown

• Rough or lumpy running

• Possible stalling

• Check fuel injector and associated wiring

• Check fuse

- Signal to ground

- Signal to B+

• Short to ground

• Open circuit or faulty connector

• Short to B+ at connector or injector

• Fuse blown

• Rough or lumpy running

• Possible stalling

• Check fuel injector and associated wiring

• Check fuse

- Signal to ground

- Signal to B+

• Short to ground

• Open circuit or faulty connector

• Short to B+ at connector or injector

• Fuse blown

• Rough or lumpy running

• Possible stalling

• Check fuel injector and associated wiring

• Check fuse

- Signal to ground

- Signal to B+

• Short to ground

• Open circuit or faulty connector

• Short to B+ at connector or injector

• Fuse blown

• Rough or lumpy running

• Possible stalling

• Check fuel injector and associated wiring

• Check fuse

- Signal to ground

- Signal to B+

• Short to ground

• Open circuit or faulty connector

• Short to B+ at connector or injector

• Fuse blown

• Rough or lumpy running

• Possible stalling

• Check fuel injector and associated wiring

• Check fuse

- Signal to ground

- Signal to B+

• Short to B+ in N71 or between N71 and pin 4 of J220

• Short to ground in N71 or between N71 and J220

• Fuse blown

• Open circuit or faulty connector at N71

• Engine speed out of range (warm idle)

• Poor throttle response in part load range

• Erratic idle

• Check N71 and associated wiring

• Check fuse

- Short to B+

- Open or short to ground

• Short to B+ in N75 or wiring between N75 and pin 23 of J220

• Short to ground in N75 or wiring between N75 and pin 23 of J220

• Fuse blown

• Open circuit or faulty connector at N75

• Boost pressure too high

• Heavy misfire during wide open throttle

• Check N75 and associated wiring

• Check fuse

• Poor ground connection to J220 at pins 10, 14, 18 or 24

• J220 faulty

• Engine does not crank and/or start

• No voltage at pin 37 of J220 while cranking

• Check J220 wiring, B+ and ground connections