G40 Impending failure?

[AndyP]

Good point, can't find a 3pin male either

[UrS4boy]

I think it's male you need coming off the g40 though. Female is on the loom side

Which is why I showed both the female pin harness connector and the G40 male pin connector with equivalent PNs (and pin PNs) in this photo:

[UrS4boy]

Good point, can't find a 3pin male either

Then you are not looking very hard. Worst comes to worst, Golf/Jetta III 3-pin O2 sensor connectors can be cut off a dead O2 sensor with say 6 inches (150 mm) or so of wire that you then splice to the new $10 Hall sender from EFI Express.

[mcandmar]

When i google the part number 000979129 all i can see are pins with a cable attached. Do you know if Audi sells them that way as i just want the pins to crimp myself.

[UrS4boy]

When i google the part number 000979129 all i can see are pins with a cable attached. Do you know if Audi sells them that way as i just want the pins to crimp myself.

That's the way Audi sells them, i.e. two pins on a short length of yellow wire that you cut and splice into the point where you need the wire. If you are using a BB Automacao G40 Hall sender, say from EFI Express, you will need to splice anyway because the leads that come with the Hall sender aren't long enough to get over to the harness connector.

EFI Express sells the raw pins sans wires.

Dave F.

[mcandmar]

As a temporary fix i fitted a second hand sensor which is working fine but i would like to sort out the new sensor and have it ready to go.

That "temporary" fix completely left my mind until last night when the bloody car refused to start. It could only happen three days before Christmas while doing some last minute shopping. Maybe its just pissed with me for not buying it a Christmas present this year

/humbug

[mcandmar]

I could do with a few suggestions here folks. I finally got around to rebuilding the unit today with a new sensor and connector and it still wont start. I am getting the error,

00515 - Camshaft Position (Hall) Sensor (G40)
04-00 - Mechanical Malfunction

Confirmed i have 5v at the sensor, and if i connect an LED across the + and trigger it blinks away as i turn the engine over so the sensor is working (and i suspect the old one may have been too).

Crank/Cam timing is all correct as i had to pull the belt to replace the sensor, and the ECU seems to know the sensor is there as i get the following error if i unplug the connector,

00515 - Camshaft Position (Hall) Sensor (G40)
30-00 - Open or Short to Plus

My next plan of attack is to disconnect the ECU and check the cabling between the ECU and sensor, after that i am at a loss. I am thinking i should check the TDC sensor pin on the flywheel (i assume it would generate a code if missing?), and the immobilizer is another possibility but i am really clutching at straws at this stage. Anybody got any ideas?

[irishs2]

Whats the condition on the key on the camshaft pulley? These can go too as I have found out . Maybe its detecting that the timing is off now.
Just a guess

[mcandmar]

Camshaft pulley was fine, though i am wondering about the lower crank pulley now that you say it, i never thought to check the mark on the flywheel when i set it to TDC. God i hope it isnt that...

[mcandmar]

The key on the crank pulley had broken so the crank/cam pulley was retarded about 10 degrees in relation to the crank, a little over one tooth at the camshaft pulley. Looking at how dirty the bits are i can only assume it has been broken for some time, and the big bolt required very little effort to undo so it didn't take much force for it to slip. As you say, the ECU was probably looking at the crank TDC sensor and the Crank position and figuring the math dont add up, hence "Mechanical Malfunction" for the G40.

I "think" i might have got away with it as 10 degrees isn't a huge amount. I'll order up a new pulley/belt to throw at it and do a compression test to see, fingers crossed!

[UrS4boy]

Sorry to hear that. Hopefully no valve damage. You might want to consider one of Tommi's billet crank pulleys.

[mcandmar]

Funny you should mention it i bought one last night from Terry for my engine build that i will probably never actually get around to. I do have a new Audi one here so i'll just use that to get the car back up and running, the long term plan is an engine swap. ....which may be the short term plan pending a compression test. Its complicated

[irishs2]

Damn, at least its only out a small amount, and didn't fail completely while driving.

Are you planning big power?

[newsh]

I really hope you got lucky there mate, there's been a few of these lately hasn't there? Do you have the correct holding tool for torquing the crankshaft bolt up?

[mcandmar]

Nothing crazy, i have a hybrid RS2 turbo, JE pistons, rods, and a bunch of RS2 parts squirreled away. I just wish i had half the motivation you have to get it done

How is the avant coming along? I haven't been on the forum in so long i'm a bit behind the times.