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How to Replace an audi key shell G28 Engine Speed Sensor

Charles the Humble Technician shows how to replace the G28 Engine Speed Sensor. This sensor is situated at the edge of transmission just above the flywheel gear. It transmits a signal to the ECU via an uncolored wire T55/49, then to the tachometer on the instrument cluster.

1. Engine Speed Sensor

The grey wire is situated on the edge of transmission, above the flywheel ring. The sensor transmits signals through the grey wire to pin T55/49. The ECU then uses this information to control fuel, timig and boost. It also sends signals to the G5 tachometer inside the instrument cluster.

The sensor serves as a reference to correlate with the G40 Camshaft Position Sensor. The ecu must be aware of when the crankshaft has reached TDC, and the location of the camshaft so that it can activate the spark and injectors.

If this sensor fails to function, the ECU will display an error code P00160. This indicates that the Crank Shaft is not in line with the Intake Camshaft. It could also indicate an issue with the chain or a jumpy chain link in the upper timing chain. The code will not appear without the additional information supplied by other sensors (G4 or G40).

It can be a bit difficult to test as there are various pins on the connector, and each one has different functions. The best method for doing this is by measuring the resistance between the ECU and the sensor. If the sensor is operational, it should be reading around 1000 ohms. Examine for signs of coolant, or oil in the connector bay if you are experiencing issues with this component.

2. Injectors

Yesterday, while accelerating from the highway paytoll at maximum speed I noticed a significant drop in power. It was as if the engine had run out of gas. Or, my injectors were not firing. I pulled out the spark plugs this morning and found that 3 were drenched in gasoline and the 4th was dry. When I start the engine without sparks, I put a piece of tissue on top of each injector hole, the 3 drenched with gazoline jump out but the 4th stays shut. I tried to test the ground connections of ECU pins 14,30, and 48/55. I got 0ohm. So i assume the problem is elsewhere.

I also tried to reset the PID with no success. The car will start when the G28 is disconnected, but it is running fine with the G28 plugged in. However, the intermittent misfire problem continues to occur at higher RPM. The temperature sensor for the coolant (G62) shows the wrong temperature of that is -49c even after unplugging it. I also noticed that the oil pressure gauge in the cockpit shows 2 bar while the actual pressure is 0.0 when I crank up the engine.

I'm not sure what to do, but i think i've pretty much ruled out everything else. But i am afraid I may have missed something. If anyone has any suggestions, Audi keyless entry please chime in! TIA!

3. Fuel Pump

The fuel pump in the g28 can be activated by a signal from the RPM sensor. The GM-style sender is identical to the G4 and both function in the 80 100, 200, Audi Car Key Case UrS and RS2 cars so you can easily find one at a wrecking yard or from a parts store. Test them out to do - just put your DMM in resistance mode and take measurements between pins 1 (with the bump on the connector end up) and 2 (2nd from left on the black connector's side). They must be infinite ohms.

4. ECU

The ECU in our 20vt turbo (3B AAN ABY ADU) engines needs to be aware of the speed and position of the crankshaft to determine timing of the fuel injector, etc. In order to do this it makes use of a Crank Position Sensor (G4) and an Engine Speed Sensor (G28). If either of these sensors go badly, you will see codes on the diagnostic scanner that can lead to engine shutdown.

A failing G28 sensor could result in an inaccurate gearbox speed counter, a gearbox that shifts more quickly than normal, or a misfire while in the gear. If you have any of these problems, it is most likely that your sensor is failing and should be replaced. The good news is that they are very cheap and readily available, especially if you're looking at the Bosch model, which is what we have. If you prefer, GM's version of this part would be a good option.

5. Tachometer

A malfunctioning engine speed sensor could be the cause of many issues with your vehicle. It's an essential component of your new audi keys's transmission, because it communicates to the ECU about how fast or slow the vehicle's crankshaft is turning. This sensor can cause the transmission to malfunction and other car components to be affected.

The G5 engine speed sensor is located on the edge of the transmission above the flywheel ring gear. It transmits a signal to the ECU at pin T55/49 via a grey wire. The ECU uses this signal to control the flow of fuel and boost as well as timig. It also sends it to the G5 Tachometer in instrument cluster. You can check the sensor for failure by checking continuity between it and the tachometer, between the ECU pin T55/49 and the instrument cluster connection via pin T6a/1 (trace [79]) and between pin T6a/1 and the instrument cluster pin T26a/12. You should detect a resistance of approximately 1000 ohms in these areas. This is a typical component across the audi tt key 80 100 200, UrS and RS2 range from 1985 MC through the 1997 UrS AAN and 1995 RS2 ADU, so the best parts could be found in wrecking yards.