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ABY / ADU Engine Wiring

A demystifying guide to schematics & cabling

Rev02 - Paul Nugent, 3rd August 2009

http://S2central.net

Introduction The purpose of this document is to itemise and describe the ABY / ADU engine wiring loom Refer to my Schematics & Wiring Primer in the first instance for any background information This document identifies all of the locations used to correctly integrate the ABY/ADU wiring into an Audi B3/B4 vehicle (or adapt to other vehicles) This information is as correct as I can make it but the reader is well advised to double check that everything is to their own satisfaction at installation.For all S2/RS2 schematics across the years and B3/B4 variants http://www.s2central.net/S2_Schematics/Rev 02 3rd August 2009 http://S2central.net 2

ABY/ADU looms over the yearsLHDABY 1992-1994 1992-1994 1995 >> Notes With anti-theft & IMMO-A With IMMO-1 Part Number 8A1 971 072 BM 8A1 971 072 GL 8A1 971 072 JB ABY 1992-1994 1992-1994 1995 >>

RHDNotes With anti-theft & IMMO-A With IMMO-1 Part Number 8A2 971 072 AG 8A2 971 072 DA 8A2 971 072 EH ** Used in this document

ADU 1994 1995,1996

Notes With anti-theft & IMMO-A With IMMO-1

Part Number 8A1 971 072 GT 8A1 971 072 JF

ADU 1994-1996

Notes With IMMO-1 ?

Part Number 8A2 971 072 EN

Rev 02 3rd August 2009

http://S2central.net

NOTE IMMO-1 uses key transponders and ECU comms IMMO-A predates that with an alternative system

3

The ABY Wiring Loom (Late RHD shown)Ancillary loom Extends from these two connectors T8e & T8f on the schematics

Engine Bay

This section inside cabin This section to relay & fusesRev 02 3rd August 2009 http://S2central.net 4

Main ABY Wiring LoomBulkhead Grommet Note This loom is RHD MY95 2 4 3

1 5Consider the loom to be composed of five sections : Bundle 1 - To the ECU - wrapped in yellow tape Bundle 2 - The heavy insulated section into the engine bay Bundle 3 - A very skinny bundle that connects to a single 2-pin plug Bundle 4 - Another skinny bundle, yellow wrapped, with two connectors at the end Bundle 5 - Big yellow bundle to the fusebox & relay blocks with a mass of spaghetti at the endRev 02 3rd August 2009 http://S2central.net 5

Bundle 1 ECU (J220) Bundle 1 connects directly to ECU by way of huge 55-pin Bosch Motronic connector01 20 38

Pin 01 at This End Pin 38 Pin 55

Pin 01

Pin 19

19 37 55

Rev 02 3rd August 2009

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ECU Pin OutJPT-5501 20 38 02 21 39 03 22 40 04 23 41 05 24 42 06 25 43 07 26 44 08 27 45 09 28 46 10 29 47 11 30 48 12 31 49 13 32 50 14 33 51 15 34 52 16 35 53 17 36 54 18 37 55 19 Rev 02 3rd August 2009 18 19 ro/ws br/ge +12V (S27) 0V 37 bl/sw 13 14 15 16 17 07 08 09 10 11 12 sw/ws gn gr br/ge ws ro/sw gn/gr ws/ro br/ro br/ro br/bl G70 / 3 G40 / 2 F96 / 1 0V G61 / 1 +5V OBD-L 0V INJ #5 INJ #2 31 32 33 34 35 36 06 gn/sw HVAC I/O 26 27 28 29 30 ws/gn sw gn gn sw/li br/sw bl bl/sw gn/ge br/gn br/ws br/sw G70 / 2 +12V (S32) G39 / T1a G66 / 1 0V ref OBC N75 / 2 INJ #3 INJ #4 INJ #1 J17 / 59 (S28) 47 48 49 50 51 52 53 54 55 ro li + gr bl ws/bl gn/li gn/bl gn/ro gn G4 / 2 0V ref G28 / 2 VSS F60 / 6 G69 / 3 OBD-K Pin 01 02 03 04 05 Colour gn/ws li br/gn gn/sw ws To N122 / 4 N122 / 3 J17 / 47 N71 / 2 N80 / 2 Pin 20 21 22 23 24 25 Colour ro/sw gn gr/br sw/bl br/ro bl/li To N127 / 4 N127 / 3 MIL N122 / 1 0V G70 / 4 Pin 38 39 40 41 42 43 44 45 46 Colour br/bl ws/sw li sw/ge sw/ge ro/gn bl/ws To Code Plug Code Plug RPM J155 / 3 G42 G62 F76 / R

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Bundle 2 Engine Room Lets break this one down into smaller cable bundles, starting from the bulkhead grommet : 2.1 Two circular multi-pin plugs and one 2-pin plug 2.2 Hefty mass of multi-pin plugs 2.3 Plugs for lambda probe 2.4 Two spades and a 2-pin plug 2.5 A 6-pin plug on its own 2.6 A grey circular plug with 2 pins 2.7 A red/black wire with single spade 2.8 A black wire with hooded eyelet connectorRev 02 3rd August 2009 http://S2central.net 8

Bundle 2.1 Engine LoomT8e F75TIP - Test connectivity from F75 to T10/1 and 0V See Bundle 5.

T8f

F75 2 pin connector for hydraulic oil level switch T8f is marked with a 1 label this side is male T8e is marked with a 2 label this side is maleRev 02 3rd August 2009 http://S2central.net 9

Locations : T8e, T8f & F75

T8e & T8fBulkhead Location 18

F75 on Hydraulic ReservoirLocation 24Rev 02 3rd August 2009 http://S2central.net 10

Bundle 2.2 So many connectors !

Bundle 2.2.A Total of 9 multi-pin plugs here 6 of them extend to various sensors by way of the bulkhead connector panel (BCP) shown on next pageRev 02 3rd August 2009

Bundle 2.2.B A fatter branch carries these to fuel injectors, inlet manifold and head

http://S2central.net

11

Bulkhead Connector Panel (BCP)2 x Power Output Stages (POS) N122 & N127

1. 2. 3. 4. 5. 6.Location Rear of cylinder head

White, Coils 4 & 5 (T3aa) White, Coils 1-2-3 (T3k) Green: Knock-1 (G61) Blue: Knock-2 (G66) Grey: Crank Speed (G28) Black: Crank Position (G4)

Note Other colours of knock sensor exist.Rev 02 3rd August 2009 http://S2central.net 12

Bundle 2.2.A.1 POS & CoilsT4g T4n T3k T3aaWarning Schematic Errors Ahead

T4g Brown, Input to POS for cyls 1-2-3 (N122) T4n Black, Input to POS for cyls 4 & 5 (N127) T3k and T3aa White, +12V supply to coils, fused by S32http://S2central.net 13

Rev 02 3rd August 2009

Factory Schematics are WRONG

#1 N164 N163 #2

1#2 #3

2

3

5

4#1

Corrections shown above annotated in red NOTE also that some variations of wire colour existRev 02 3rd August 2009 http://S2central.net 14

The Correct POS TopologyCredit Dave Forgie for the X-Ray POS image

OUTPUT 1 2 3

1 2 3

INPUT4 3 2 1 Channel 01 Channel 02 0V Channel 03

Coil Pack per Cylinder 1 2 3 4 5Rev 02 3rd August 2009

ECU Pin Number / 55 1 2 23 20 21

Common Wire Colours gn/ws li sw/bl ro/sw gnhttp://S2central.net

POS-1 (N122) BROWN Ch 01, T4g/4 Ch 02, T4g/3 Ch 03, T4g/1 -

POS-2 (N127) BLACK Ch 01, T4n/4 Ch 02, T4n/3

* Channel 03 on POS-2 is not used.

15

Coilpack wiring from POS-1 & 2WHITEsw sw sw 3 2 1

COILPACKS

OUTPUT3 2 1

INPUT1 2 3 4 CH3 unused 0V gn CH2 ro/sw CH1

5 4

N127 POS-2

T3aa15

JPT-3

T3ab

21 20

T4n ECU pinINPUT1 2 3 4 CH3 0V CH2 CH1 sw/bl li gn/ws 23 02 01

S32 20Asw sw sw

WHITE3 2 1

3 2 1Front

OUTPUT3 2 1

N122 POS-1

T3k

JPT-3

T3p

T4g ECU pin

Coilpacks have integral connector with flying leads that must be correctly spliced into JPT-3 connectors as shown logically above. Note that POS drawn upside down here to align with cylinder direction. POS units must have thermal paste on the connection to bulkhead.http://S2central.net 16

Rev 02 3rd August 2009

Bundle 2.2.A.2 Throttle Position Sensor

G69 / F60

Connects directly to the throttle body

Rev 02 3rd August 2009

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17

Bundle 2.2.A.3 Knock & Crank Sensors

Knock

Crank BLACK : T3l Crankshaft Position Sensor (G4) GREY : T3m Crankshaft Speed Sensor (G28) Note that other coloured Knock Sensor 1 (G61) GREEN : T3n knock sensors were used Knock Sensor 2 (G66) BLUE : T3o in different years. Checkyour own wiring carefully.Rev 02 3rd August 2009 http://S2central.net 18

Locations Knock & Crank Sensors

G4G61 G66

G28

Location Left side of engine block

Location Left side of engine block Low down near bellhousing.

G61 - Knock-1 (Cyls 1-2-3) G66 - Knock-2 (Cyls 4 & 5)Rev 02 3rd August 2009

G4 - Crank Position Sensor G28 - Crank Speed Sensorhttp://S2central.net 19

Bundle 2.2.B.1 IAT, ISV & Earth

N71 G42 0V

G42 Intake Air Temp Sensor N71 Idle Stabiliser Valve Earth Points at inlet manifold. Ensure each eyelet has two wires firmly crimped on and that a good clean connection is made with the manifold.

Tip Check connectivity from this earth point to all of the others in loom.

Rev 02 3rd August 2009

http://S2central.net

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Locations IAT, ISV & Earths G42 - IAT Location 14 N71 - ISV Location 13 Earth on inlet manifold

X

X

Rev 02 3rd August 2009

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21

Bundle 2.2.B.2 EVAP & CTSG62 N80

G62 Coolant Temp Sensor N80 EVAP purge valveRev 02 3rd August 2009 http://S2central.net 22

Locations : EVAP & CTS

N80 EVAP purge valveBehind / Under Inlet pipe

G62 Coolant Temp SensorRear of cylinder head

Rev 02 3rd August 2009

http://S2central.net

23

Bundle 2.2.B.3 Injectors & CamshaftFuel Injectors for cylinders 1 through 5 from left to right

1

2

3

4 5

G40 Location Under Camshaft PulleyRev 02 3rd August 2009 http://S2central.net

G4024

Bundle 2.3 Lambda Probe

Z19G39

T1a G39Z19Location Near right strut

Rev 02 3rd August 2009

http://S2central.net

25

Bundle 2.4 Brakes & ServoF21 F34F34 F21

F21 two spades onto hydraulic servo unit F34 2-pin JPT (grey) for brake fluid level TIP Test connectivity to T5, T10 & 0VRev 02 3rd August 2009 http://S2central.net 26

Bundle 2.5 - MAF

G70

Self explanatory Location 2